U.S. patent application number 14/043798 was filed with the patent office on 2015-04-02 for shingle with dual sealant.
The applicant listed for this patent is Buikling Materials Investment Corporation. Invention is credited to Olan Leitch.
Application Number | 20150089895 14/043798 |
Document ID | / |
Family ID | 52738732 |
Filed Date | 2015-04-02 |
United States Patent
Application |
20150089895 |
Kind Code |
A1 |
Leitch; Olan |
April 2, 2015 |
SHINGLE WITH DUAL SEALANT
Abstract
The present disclosure relates, according to some embodiments,
to articles, systems, methods of use, methods of manufacturing, and
methods of packing roofing shingles with dual sealants. A shingle
may comprise, in some embodiments, a headlap region comprising a
top headlap surface and a back headlap surface; a buttlap region
comprising a top buttlap surface and a back buttlap surface. A top
headlap surface may comprise a first sealant and/or a back headlap
surface may comprise a second sealant.
Inventors: |
Leitch; Olan; (Bakersfield,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Buikling Materials Investment Corporation |
Wilmington |
DE |
US |
|
|
Family ID: |
52738732 |
Appl. No.: |
14/043798 |
Filed: |
October 1, 2013 |
Current U.S.
Class: |
52/518 ;
52/746.11 |
Current CPC
Class: |
E04D 1/28 20130101; E04D
1/26 20130101; E04D 2001/3435 20130101 |
Class at
Publication: |
52/518 ;
52/746.11 |
International
Class: |
E04D 1/28 20060101
E04D001/28 |
Claims
1. A shingle comprising: a headlap region comprising a top headlap
surface having a first conditional sealant, and a back headlap
surface; a buttlap region comprising a top buttlap surface, and a
back buttlap surface having a second conditional sealant; wherein
the first conditional sealant and/or the second conditional sealant
are each formulated to have substantially no adhesiveness alone,
but become adhesive upon contact with the other.
2. A shingle according to claim 1, wherein the first sealant and
second sealant have substantially stripe-shaped geometries.
3. A shingle according to claim 1, wherein the first sealant is
about 0.2 inches to about 0.6 inches wide, the second sealant is
about 0.2 inches to about 0.6 inches wide or the first sealant and
the second sealant are each about 0.2 inches to about 0.6 inches
wide.
4. A shingle according to claim 1, wherein the first sealant and
the second sealant have substantially the same shape and
substantially the same size.
5. A shingle according to claim 1, wherein the first sealant
extends along a lower edge of the top headlap surface, the second
sealant extends along a lower edge of the back buttlap surface, or
both the first sealant extends along the lower edge of the top
headlap surface and the second sealant extends along the lower edge
of the back buttlap surface.
6. A shingle according to claim 1, wherein the first sealant and
the second sealant have substantially the same composition.
7. A roofing system for cladding a structure; the roofing system
comprising: a first shingle and a second shingle wherein each
shingle comprises a headlap region comprising a top headlap surface
having a first conditional sealant, and a back headlap surface; a
buttlap region comprising a top buttlap surface, and a back buttlap
surface having a second conditional sealant; wherein the first
conditional sealant and the second conditional sealant are each
formulated to have substantially no adhesiveness alone, but become
adhesive upon contact with the other, and wherein the first sealant
of the first shingle is aligned with and contacts the second
sealant of the second shingle.
8. A roofing system according to claim 7 further comprising a third
shingle, wherein the second sealant of the first shingle is aligned
with and contacts a first sealant of the third shingle.
9. A roofing system according to claim 7, wherein the first sealant
and second sealant of each shingle have substantially stripe-shaped
geometries.
10. A roofing system according to claim 7, wherein the first
sealant and second sealant of each shingle have substantially the
same shape and substantially the same size.
11. A roofing system according to claim 7, wherein the first
sealant of each shingle is about 0.2 inches to about 0.6 inches
wide, the second sealant of each shingle is about 0.2 inches to
about 0.6 inches wide or the first sealant and the second sealant
of each shingle are about 0.2 inches to about 0.6 inches wide.
12. A roofing system according to claim 7, wherein the first
sealant and the second sealant of each shingle have substantially
the same composition.
13. A method for cladding a structure comprising a substrate, the
method comprising: providing a first shingle and a second shingle,
wherein each shingle comprises a headlap region comprising a top
headlap surface having a first conditional sealant, and a back
headlap surface, a buttlap region comprising a top buttlap surface,
and a back buttlap surface having a second conditional sealant; and
contacting the first sealant of the first shingle and the second
sealant of the second shingle, wherein the first conditional
sealant and the second conditional sealant are each formulated to
have substantially no adhesiveness alone, but become adhesive upon
contact with the other.
14. A method according to claim 13 further comprising providing a
third shingle, and contacting the second sealant of the first
shingle and a first sealant of the third shingle.
15. A method according to claim 13, wherein the first sealant and
second sealant of each shingle have substantially stripe-shaped
geometries.
16. A method according to claim 13, wherein the first sealant and
second sealant of each shingle have substantially the same shape
and substantially the same size.
17. A method according to claim 13, wherein the first sealant of
each shingle is about 0.2 inches to about 0.6 inches wide, the
second sealant of each shingle is about 0.2 inches to about 0.6
inches wide or the first sealant and the second sealant of each
shingle are about 0.2 inches to about 0.6 inches wide.
18. The method according to claim 13, wherein the first sealant and
the second sealant of each shingle have substantially the same
composition.
19. A method for manufacturing a shingle, the method comprising:
providing a shingle, the shingle comprising a headlap region
comprising a top headlap surface and a back headlap surface, and a
buttlap region comprising a top buttlap surface and a back buttlap
surface; providing a first conditional sealant on the top headlap
surface; and providing a second conditional sealant on the back
buttlap surface; wherein the first conditional sealant and the
second conditional sealant are each formulated to have
substantially no adhesiveness alone, but become adhesive upon
contact with the other.
20. The method according to claim 19, wherein the first sealant and
second sealant have substantially stripe-shaped geometries.
21. The method according to claim 19, wherein the first sealant and
the second sealant have substantially the same shape and
substantially the same size.
22. The method according to claim 19, wherein the first sealant is
about 0.2 inches to about 0.6 inches wide, the second sealant is
about 0.2 inches to about 0.6 inches wide or the first sealant and
the second sealant are each about 0.2 inches to about 0.6 inches
wide.
23. The method according to claim 19, wherein providing a first
conditional sealant on the top headlap surface further comprises
providing the first sealant on the top headlap surface along a
lower edge of the headlap and providing a second conditional
sealant on the back buttlap surface further comprises providing the
second conditional sealant on the back buttlap surface along a
lower edge of the buttlap.
24. An assembly of shingles, the assembly comprising: a first
shingle and a second shingle wherein each shingle comprises a
headlap region comprising a top headlap surface having a first
conditional sealant, and a back headlap surface; a buttlap region
comprising a top buttlap surface, and a back buttlap surface having
a second conditional sealant; wherein the first conditional sealant
and the second conditional sealant are each formulated to have
substantially no adhesiveness alone, but become adhesive upon
contact with the other, and wherein the top headlap surface of the
first shingle is substantially aligned with and contacts the back
buttlap surface of the second shingle; wherein the top buttlap
surface of the first shingle is substantially aligned with and
contacts the back headlap surface of the second shingle; wherein
the first sealant and second sealant of each shingle have
substantially stripe-shaped geometries; and wherein the first
sealant of each shingle is about 0.2 inches to about 0.6 inches
wide and the second sealant of each shingle is about 0.2 inches to
about 0.6 inches wide.
25. A method of packing an assembly of shingles, the method
comprising: providing a first shingle and a second shingle wherein
each shingle comprises a headlap region comprising a top headlap
surface having a first conditional sealant, and a back headlap
surface; a buttlap region comprising a top buttlap surface, and a
back buttlap surface having a second conditional sealant; wherein
the first conditional sealant and the second conditional sealant
are each formulated to have substantially no adhesiveness alone,
but become adhesive upon contact with the other, and positioning
the top headlap surface of the first shingle to be substantially
aligned with and contacting the back buttlap surface of the second
shingle; positioning the top buttlap surface of the first shingle
to be substantially aligned with contact the back headlap surface
of the second shingle; wherein the first sealant and second sealant
of each shingle have substantially stripe-shaped geometries; and
wherein the first sealant of each shingle is about 0.2 inches to
about 0.6 inches wide and the second sealant of each shingle is
about 0.2 inches to about 0.6 inches wide.
Description
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates, in some embodiments, to
articles, systems, and methods for roofing a structure including,
for example, shingles comprising a first and second sealant.
BACKGROUND OF THE DISCLOSURE
[0002] Roofing materials such as shingles may be used to clad a
structural surface such as a roof with a roofing substrate. Such
shingles may have a sealant that allows a shingle to adhere to
another shingle, a structure, or a substrate. If the adhesion is
too weak, a shingle may become loose and may result in structural
instability of an entire roofing system. Structurally unstable
roofing systems may create hazardous conditions for occupants in
the building on which the roofing system is assembled. Structurally
unstable roofing systems may also be costly to repair. Shingles
with weak sealants also may not be appropriate for roofing
structures with steep slopes or roofing systems that may often be
subjected to strong winds or high heat conditions.
[0003] Roofing materials such as shingles may be sold in bulk and
may be packaged as assemblies. Assemblies may not be packaged in
the most secure or space-efficient manner. Inefficient usage of
space may increase packaging costs and shipping costs. Improperly
secured shingles may be damaged during shipping. Another problem
that occurs in packaging of shingles is that a sealant of a shingle
may be inadvertently exposed to another surface during packaging or
while inside the packaging. Inadvertent exposure may result in a
sealant adhering to an undesired surface. As a result, an adhesive
quality of a sealant may be compromised and the shingle may become
unusable.
SUMMARY
[0004] Accordingly, a need has arisen for improved shingles that
have greater bond or sealant strength, increased stability, and
greater ease and space-efficiency in packaging. More specifically,
it may be desirable to have a shingle assembly that promotes
space-efficient packaging and prevent inadvertent adherence of a
sealant to an undesired surface. It may also be desirable to have a
shingle system wherein shingles may form strong bonds or a strong
adhesion.
[0005] The present disclosure relates, according to some
embodiments, to articles, systems, methods of use, methods of
manufacturing, assemblies of, and methods of packing roofing
shingles for cladding a structure. For example, a dual sealant
shingle may comprise a headlap region with a top headlap surface
and a back headlap surface; a buttlap region with a top buttlap
surface and a back buttlap surface. A top headlap surface may
comprise a sealant (e.g., a first sealant). A back headlap surface
may comprise a sealant (e.g., a second sealant). A sealant may be a
conditional sealant, in some embodiments. For example, a sealant
may be formulated to become adhesive (e.g., tacky, sticky) upon
contact with another composition (e.g., a sealant of like or
different composition on another shingle). In some embodiments,
first and/or second sealants independently may have substantially
stripe-shaped geometries. A sealant may be positioned on a top
headlap surface closer to the middle of the shingle than the upper
edge of the shingle in some embodiments. For example, a sealant may
be positioned on a top headlap surface near (e.g., adjacent) and/or
substantially parallel to the lower edge of the headlap and/or
upper edge of the buttlap. A sealant may be positioned on a back
buttlap surface closer to the lower edge of the shingle than the
middle of the shingle, in some embodiments. For example, a sealant
may be positioned on a back buttlap surface near (e.g., adjacent)
and/or substantially parallel to the lower edge of the shingle
(e.g., opposite the headlap and/or parallel to the bottom edge of
the buttlap). First and/or second sealants independently may have
substantially the same shape and/or substantially the same size
according to some embodiments. A first sealant may be about 0.2
inches to about 0.6 inches wide, a second sealant may be about 0.2
inches to about 0.6 inches wide or a first sealant and a second
sealant may be each about 0.2 inches to about 0.6 inches wide. In
some embodiments, a first sealant and a second sealant may have
substantially the same composition.
[0006] The present disclosure relates, in some embodiments, to
roofing systems for cladding a structure. For example, a roofing
system may comprise a first dual sealant shingle and a second dual
sealant (e.g., each as described above), wherein the first sealant
of the first shingle is aligned with and contacts the second
sealant of the second shingle. A roofing system may further
comprise a third dual sealant shingle, wherein the second sealant
of the first shingle is aligned with and contacts the first sealant
of a third shingle. A second shingle may be laterally offset from
the first shingle and/or a third shingle, if present, may be
aligned with a first shingle or laterally offset from a first
and/or second shingle. In some embodiments, contact between
sealants may be substantially coextensive, for example, where
sealant strips are laterally and vertically aligned, or partial,
for example, where sealant strips are vertically aligned and
laterally offset.
[0007] According to some embodiments, the present disclosure
relates to methods for cladding a structure comprising a substrate
(e.g., a roof deck). For example, a method may comprise providing a
first dual sealant shingle and a second dual sealant (e.g., each as
described above) and/or contacting the first sealant of the first
shingle and the second sealant of the second shingle. A method may
further comprise, in some embodiments, providing a third shingle,
and contacting the second sealant of the first shingle and the
first sealant of a third shingle. A method may comprise positioning
a first dual sealant shingle, a second dual sealant, and a third
dual sealant (e.g., each as described above), wherein a lateral
edge of the first shingle abuts a lateral edge of the second
shingle, the first sealant of the first shingle is collinear with
the first sealant of the second shingle, a portion of the second
sealant of the third shingle contacts a portion of the first
sealant of the first shingle, and/or a portion of the second
sealant of the third shingle contacts a portion of the first
sealant of the second shingle.
[0008] The present disclosure relates, in some embodiments, to
methods for manufacturing a shingle. For example, a method of
manufacturing a shingle may comprise (a) providing a shingle
comprising a headlap region (e.g., comprising a top headlap surface
and a back headlap surface) and a buttlap region (e.g., comprising
a top buttlap surface and a back buttlap surface), (b) providing a
first conditional sealant (e.g., on the top headlap surface),
and/or (c) providing a second conditional sealant (e.g., on the
back buttlap surface), wherein the first conditional sealant and/or
the second conditional sealant are formulated to have substantially
no adhesiveness alone, but become adhesive upon contact with the
other. A manufacturing method may comprise at least partially
covering (e.g., substantially covering, covering) the first sealant
with a release tape, at least partially covering the second sealant
with a release tape, or at least partially covering the first
sealant and the second sealant with a release tape.
[0009] The present disclosure relates, in some embodiments, to
assemblies of shingles (e.g., non-adhered shingles). An assembly of
shingles may comprise, for example, a first dual sealant shingle
and a second dual sealant (e.g., each as described above), wherein
(a) the top surface of the first shingle may contact back surface
of the second shingle, (b) the outer edges of the first and second
shingles may be at least partially aligned (e.g., substantially
aligned, aligned), and (c) the second shingle may be arranged
180.degree. from the first shingle (e.g., the upper edge of the
first shingle is adjacent to the lower edge of the second shingle
and/or the upper edge of the second shingle is adjacent to the
lower edge of the first shingle). In some embodiments, an assembly
of shingles may comprise a first dual sealant shingle and a second
dual sealant (e.g., each as described above), wherein (a) the top
headlap surface of the first shingle may be at least partially
aligned (e.g., substantially aligned, aligned) with the back
buttlap surface of the second shingle, (b) the top headlap surface
of the first shingle may at least partially contact (e.g.,
substantially contact, contact) the back buttlap surface of the
second shingle, (c) the top buttlap surface of the first shingle
may be at least partially aligned (e.g., substantially aligned,
aligned) with the back headlap surface of the second shingle, (d)
the top buttlap surface of the first shingle may at least partially
contact (e.g., substantially contact, contact) the back headlap
surface of the second shingle, and/or (e) the second shingle may be
arranged 180.degree. from the first shingle (e.g., the tabs of the
first shingle and the tabs of the second shingle face opposite
directions).
[0010] According to some embodiments, the present disclosure
provides methods for packing assemblies of shingles. For example, a
method may comprise providing a first dual sealant shingle and a
second dual sealant (e.g., each as described above) and positioning
the first and second shingle wherein (a) the top surface of the
first shingle may contact back surface of the second shingle, (b)
the outer edges of the first and second shingles may be at least
partially aligned (e.g., substantially aligned, aligned), and (c)
the second shingle may be arranged 180.degree. from the first
shingle. A packing method may comprise, according to some
embodiments, (a) positioning a top headlap surface of a first
shingle to be at least partially aligned (e.g., substantially
aligned, aligned) with a back buttlap surface of a second shingle,
(b) positioning the top headlap surface of the first shingle to at
least partially contact (e.g., substantially contact, contact) the
back buttlap surface of the second shingle, (c) positioning a top
buttlap surface of the first shingle to be at least partially
aligned (e.g., substantially aligned, aligned) with a back headlap
surface of the second shingle, and/or (d) positioning the top
buttlap surface of the first shingle to at least partially contact
(e.g., substantially contact, contact) the back headlap surface of
the second shingle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Some embodiments of the disclosure may be understood by
referring, in part, to the present disclosure and the accompanying
drawings, wherein:
[0012] FIG. 1A illustrates a top view of a shingle according to an
example embodiment of the disclosure;
[0013] FIG. 1B illustrates a back view of the shingle shown in FIG.
1A;
[0014] FIG. 2A illustrates a back perspective view of an assembly
of shingles according to an example embodiment of the
disclosure;
[0015] FIG. 2B illustrates a profile view of the assembly of
shingles shown FIG. 2A;
[0016] FIG. 3A illustrates a top perspective view of an assembly of
shingles according to an example embodiment of the disclosure;
[0017] FIG. 3B illustrates a profile view of the assembly of
shingles shown in FIG. 3A;
[0018] FIG. 4A illustrates a top view of a shingle according to an
example embodiment of the disclosure;
[0019] FIG. 4B illustrates a back view of the shingle shown in FIG.
4A;
[0020] FIG. 4C illustrates a profile view of an assembly of
shingles according to an example embodiment of the disclosure;
[0021] FIG. 5A illustrates a profile view of an assembly of
shingles according to an example embodiment of the disclosure;
[0022] FIG. 5B illustrates a more detailed view of a portion of the
assembly of shingles shown in FIG. 5A;
[0023] FIG. 5C illustrates a more detailed view of a portion of the
assembly of shingles shown in FIG. 5A;
[0024] FIG. 6 illustrates a profile view of an assembly of shingles
according to an example embodiment of the disclosure;
[0025] FIG. 7 illustrates a top view of two shingles aligned
according to an embodiment of the disclosure.
[0026] Table 1 below includes the reference numerals used in this
application. Similar structures share matching tens and ones
digits.
TABLE-US-00001 TABLE 1 Feature Name FIG. 1A FIG. 1B FIG 2A FIG. 2B
FIG. 3A FIG. 3B FIG. 4A Shingle System 200 200 400 400 Shingle 101
101 201, 301 201, 301 401, 501 401, 501 601 Headlap Region 102 102
402, 502 402, 502 602 Buttlap Region 104 104 404, 504 404, 504 604
Top Surface 205, 305 205, 305 405, 505 Top Headlap Surface 106 406,
506 406, 506 606 Back Surface 207, 307 207, 307 407, 507 Back
Headlap Surface 108 408, 508 Top Buttlap Surface 110 410, 510 410,
510 610 Sealant 111 311 411, 511 411, 511 611 Back Buttlap Surface
112 412, 512 Sealant 113 213 413, 513 Tape 114 414, 514 414, 514
614 Tape 116 416, 516 Tabs 118 118 418, 518 618 Spacings 120 120
420, 520 620 First Layer 622 Second Layer 624 Upper Edge 130 130
630 Lower Edge 131 131 631 Feature Name FIG. 4B FIG. 4C FIG. 5A
FIG. 5B FIG. 5C FIG. 6 FIG. 7 Shingle System 600 700 900 1100
Shingle 601 601 701, 801 701, 801 701, 801 901, 1001 1101, 1201
Headlap Region 602 602 902, 1002 Buttlap Region 604 604 904, 1004
Top Surface 805 Top Headlap Surface 606 806 806 706, 806 906, 1006
Back Surface 707 Back Headlap Surface 608 608 708 808 708, 808 908,
1008 Top Buttlap Surface 610 810 710 710, 810 910, 1010 Sealant
611, 611' 711, 811 711, 811 911, 1011 1111, 1211 Back Buttlap
Surface 612 612 712 712 712, 812 912, 1012 Sealant 613 613 713 913,
1013 Tape 614, 614' 814 814 914, 1014 1114, 1214 Tape 616 616 716
716, 816 916, 1016 Tabs 1118, 1218 Spacings 1120 First Layer 622
622 922, 1022 Second Layer 624 624 924, 1024 Upper Edge 630 730
930, 1030 Lower Edge 631 831 931, 1031
DETAILED DESCRIPTION
[0027] The present disclosure relates, according to some
embodiments, to articles, systems, methods of use, methods of
manufacturing, and methods of packing roofing shingles for cladding
a structure. More specifically, the present disclosure relates, in
some embodiments, to shingles comprising a first and second
sealant. Benefits of articles, systems, and methods may include, in
some embodiments, increased sealant strength, increased stability,
greater ease of packaging, and/or greater ease of assembly.
Articles
[0028] The present disclosure relates, according to some
embodiments, to shingles (e.g., asphalt shingles) with dual
sealants. According to some embodiments, a shingle with dual
sealants may comprise a headlap region, a buttlap region, a first
sealant, and a second sealant. A headlap region may comprise a top
headlap surface and a back headlap surface. A buttlap region may
comprise a top buttlap surface and a back buttlap surface. A top
headlap surface may comprise a first sealant. A back headlap
surface may comprise a second sealant.
[0029] According to the present disclosure, various materials may
be suitable for use as a composition of a headlap region, buttlap
region, first sealant, or second sealant. For example, a headlap or
buttlap region may comprise any number of materials such as a
metallic substrate (e.g., steel, an alloy, copper, aluminum, and
combinations thereof), a polymeric substrate (e.g., thermoplastic
polyolefin), or asphalt. In some embodiments, an article may be or
may comprise an asphalt shingle with dual sealants (e.g., dual
conditional sealants). First and second sealants may have
compositions that are the same or different. According to the
present disclosure, materials for various components may be varied
as desired or required.
[0030] Various types or structures of shingles may be formed with a
dual adhesive. For example, shingles structures may include, for
example, 3-tab and/or dragon's tooth configurations.
[0031] A sealant bond strength may be greater on a surface to which
it is factory-applied. When a sealant is factory-applied to
surface, a sealant may exhibit a stronger adhesive quality on the
side to which it was factory-applied to than on the side to which
it is adhered to after factory manufacturing (e.g., after adhesive
has dried, set, and/or cured). For example, an adhesive may be
originally applied to a first surface and a second surface may be
later (e.g., after the adhesive has cured) contacted with the
adhesive to form a bond. Upon separation of these first and second
surfaces, the break may be more likely to occur between the
adhesive and the second surface than between the adhesive and the
original surface. Accordingly, factory-applied sealants may be said
to form a stronger bond on the side to which they were
originally-applied.
[0032] The present disclosure may provide, in some embodiments,
improved bond strength by joining shingles with an
adhesive-adhesive bond. For example, a first sealant and a second
sealant applied to or disposed on opposing sides of adjacent
shingles (e.g., adjacent top and back surfaces, or adjacent buttlap
and headlap regions). According to some embodiments, the first and
second sealant may contact each other and form a bond. A
sealant-sealant bond may be about as strong or stronger than an
original sealant-shingle bond, according to some embodiments. Thus,
a shingle joined to adjacent shingles through one or more
adhesive-adhesive bonds may have greater bond strength and/or
greater adhesion over shingles or systems joined without
adhesive-adhesive bonds, those joined only with
shingle-sealant-shingle bonds).
[0033] According to some embodiments, a first sealant and/or a
second sealant may comprise material that does not become adhesive
until contact or mating with another sealant. For example, on its
own, a first sealant and/or a second sealant may not have an
adhesive quality. An absence of adhesiveness may reduce problems
associated with a shingle's adhesive region adhering to or affixing
to undesired material. Such undesired material may include a wrong
shingle surface, dust and specks, packaging material of the shingle
itself, and others. A first sealant and/or a second sealant may
only become adhesive, according to some embodiments, upon contact
or upon mating with a particular material. For example, in some
embodiments, a top headlap surface may comprise a first sealant
("sealant A") and a back headlap surface may comprise a second
sealant ("sealant B"). Sealant A may be chosen such that it does
not become adhesive until contact with a material of sealant B.
Sealant B independently may be a material that does not become
adhesive until contact with a material of sealant A. Thus, sealant
A and sealant B would not become adhesive until contact with one
another. Accordingly, sealant A on a top headlap surface of one
shingle may selectively mate with sealant B on a top buttlap
surface of another shingle. Conditional sealants (e.g.,
contact-activated adhesive materials) may be selected and/or
formulated, according to some embodiments, to become adhesive in
seconds, minutes, hours, or days as desired.
[0034] In some embodiments, a first sealant or second sealant may
vary in composition or materials. Different sealants may be
selected, according to some embodiments, as being more appropriate
or desirable for use in combination with particular materials used
for a buttlap and/or headlap regions of a shingle. In some
embodiments, a first sealant and second sealant may be a laminate
adhesive, bituminous based adhesive, an asphalt adhesive, a
modified asphalt adhesive, or combinations thereof. In some
embodiments, a first sealant and second sealant may comprise an
active component, such as polyester acrylate, resorcinol, phenol,
epoxy, isocyanate acrylic, and the like. A conditional sealant
composition may not be operative as an adhesive unless it is in
contact with a mated conditional sealant composition. Mated
conditional sealants may have the same composition or different
compositions. In some embodiments, a first conditional sealant and
a second conditional sealant become adhesive upon contact alone
(e.g., not upon exposure to heat and/or radiation).
[0035] According to some embodiments, a first sealant and second
sealant may each vary in geometry and/or surface area. In some
embodiments, a first sealant and second sealant independently may
each comprise a substantially stripe-shaped geometry. A first
sealant and second sealant may or may not have the same shape
and/or size as one another. In some embodiments, having a first
sealant and a second sealant of either different sizes or same
sizes may be beneficial or promote proper alignment of the two
features under different circumstances.
[0036] A first sealant and second sealant, in some embodiments, may
each be substantially covered with a release tape. Release tape may
contact sealant, for example, during packing and shipping. In some
embodiments, release tape may prevent undesired exposure of a
sealant. Such undesired exposure may be to materials including a
wrong shingle surface, dust and specks, packaging material of the
shingle itself, and others.
[0037] According to some embodiments, release tape may vary in
composition or materials. Different types of release tapes may be
selected as being more appropriate or desirable for use in
combination with particular materials used for a first sealant
and/or second sealant. According to some embodiments, release tape
may be disposed on shingle in a non-removable manner. In some
embodiments, release tape may be removable.
[0038] According to some embodiments, a first sealant and/or second
sealant independently may have a width of about 0.2 inches to about
0.6 inches. A first sealant and/or a second sealant independently
may be, in some embodiments, 0.38 inches wide. A sealant may swell,
in some embodiments, upon contact with another sealant. For
example, a conditional sealant may swell up to about 100% upon
contact with another conditional sealant material. In some
embodiments, a release tape may be sized according to the
swellability of conditional sealants present. For example, a
release tape strip may be about 2 to about 5 times as wide as a
conditional sealant strip. In some embodiments, a width of a
release tape may be greater than twice the width of a conditional
sealant. For example, a release tape may be about 11/4'' wide and a
sealant may be about 3/8'' wide. An over-sized release tape may be
desirable, for example, where a conditional sealant may have some
tendency to swell during shipping, despite the absence of contact
with a corresponding conditional sealant. A release tape may be
about 1.25 inches wide and span up to about the full length of a
shingle. A release tape and/or a sealant may be positioned on a
shingle to be approximately centered relative to each other.
[0039] Dual sealants may be applied, according to some embodiments,
to various roofing shingles. Shingles may contain one or more tabs
in a buttlap region. Tabs may be defined by inter-tab openings of
particular widths. Inter-tab openings and/or tabs may have any
desired size or shape to suit aesthetic and/or functional goals.
For example, dragon's tooth shingles may have tabs with a generally
trapezoidal configuration.
[0040] According to some embodiments, a roofing shingle may
comprise sealant strips. Sealant strips may be disposed on a back
buttlap surface and/or a top headlap surface. In some embodiments,
a roofing shingle may comprise sealant strips on both a back
buttlap surface and a top headlap surface. A sealant strip, in some
embodiments, may extend laterally across a shingle generally
parallel to a top and/or bottom edge. A sealant strip may mark the
presence and/or location of a release tape on the opposite surface
of a shingle according to some embodiments. Sealant strips may be
deposited as a solid line and/or as a dashed line.
Systems
[0041] The present disclosure relates, according to some
embodiments, to roofing systems comprising shingles with dual
sealants. In some embodiments, a first sealant and second sealant
of shingles may comprise material that does not become adhesive
until contact with another sealant. In some embodiments, a first
sealant and second sealant of shingles may each vary in geometry
and/or surface area. In some embodiments, a first sealant and
second sealant of shingles may each be substantially covered with a
release tape. In some embodiments, a first sealant and second
sealant may have a width of about 0.2 inches to about 0.6
inches.
[0042] A roofing system, in some embodiments, may be configured
such that up to about 100% of a substrate (roof deck) is covered by
at least one layer of shingles in accordance with the present
disclosure. This may be achieved, for example, by arranging each
shingle such that it overlaps at least a portion of a shingle
immediately below. More specifically, at least a portion of a
contiguous upper region of a first shingle may overlap at least a
portion of a contiguous lower region of a second shingle.
[0043] According to some embodiments of the present disclosure, a
roofing system may comprise a plurality of shingles wherein the
overlap is affixed through the use of a first sealant and a second
sealant. In some embodiments, a first sealant provided on a top
headlap surface of one shingle may contact a second sealant
provided on a back headlap surface of another shingle. Thus, a top
headlap surface of a first shingle may be overlapped by a portion
(e.g., a lower portion) of a back headlap surface of a second
shingle.
[0044] In some embodiments, a system may be configured and arranged
for use on any type of roofing decking and at any pitch, slope, or
angle. Dual sealant shingle systems may have, according to some
embodiments, stronger bonds (e.g., inter-shingle bonds) than single
sealant systems. Stronger adhesion in a system may prevent shingles
from becoming loose and may prevent structural instability of
roofing systems. Dual sealant shingle systems may include shingle
A-sealant-A-sealant-B-shingle B bonds. Bond strength between
shingles bonded with a shingle-sealant-sealant-shingle bond may be
assessed by any desirable metric. In some embodiments, a
shingle-sealant-sealant-shingle bond may be strong enough to meet
or exceed wind resistance requirements (e.g., building code). For
example, dual sealant shingles with sealant-sealant bonds near the
lower edge may be meet or exceed hurricane performance requirements
(e.g., resist uplift and/or separation under sustained winds of
about 130 miles per hour).
Methods of Use
[0045] The present disclosure relates, according to some
embodiments, to methods for cladding a structure comprising a
substrate (e.g., a roof deck). More specifically, methods for
cladding a substrate may comprise securing shingles to a substrate
(e.g., dual sealant shingles). According to some embodiments of the
present disclosure, a method of cladding a structure may comprise
contacting a first sealant of one shingle with a second sealant of
another shingle. For example, a method may include optionally
applying a first dual sealant shingle to a roofing substrate or
otherwise providing a roofing substrate with an affixed first dual
sealant shingle. A method may comprise removing tape, if present,
from a top headlap surface sealant of the first shingle and/or a
back headlap surface sealant of a second dual sealant shingle.
Contacting sealants in adjacent shingles may include, according to
some embodiments, positioning a second shingle with respect to a
first shingle so that the back headlap sealant of the second
shingle is aligned with the top headlap sealant of the first
shingle. Once positioned, the second shingle may be laid on the
first shingle, thereby bringing the first and second sealants into
contact. A method may comprise removing tape, if present, from a
top headlap surface sealant of the second shingle and/or a back
headlap surface sealant of a third dual sealant shingle,
positioning the third shingle with respect to the second shingle so
that the back headlap sealant of the third shingle is aligned with
the top headlap sealant of the second shingle, and/or laying the
third shingle on the second. A method may comprise laterally
offsetting successive shingles, for example, to avoid forming
vertical seams that could admit water.
[0046] A method may comprise using a guide strip disposed on a
shingle to align a shingle with another shingle. A method may
comprise aligning a guide strip on a first shingle with a sealant
strip on a second shingle. Aligning may include, in some
embodiments, positioning a guide strip on a first shingle
substantially parallel to and substantially immediately over a
sealant strip on a top headlap surface of a second shingle.
Methods of Making
[0047] The present disclosure relates, according to some
embodiments, to methods of making or manufacturing shingles with
dual sealants suitable for cladding a structure comprising
substrate. Methods may comprise providing a shingle with a headlap
region and a buttlap region, wherein a headlap region may comprise
a top headlap surface and a back headlap surface, and wherein a
buttlap region may comprise a top buttlap surface and a back
buttlap surface. Methods may further comprise providing (e.g.,
applying, depositing, spraying, injecting) a first sealant on a top
headlap surface, and/or providing (e.g., applying, depositing,
spraying, injecting) a second sealant on a back headlap
surface.
[0048] A method may comprise forming a desired shape for the
shingle using a desired material. A desired shape may be
substantially rectangular or mat-like in geometry. A desired
material may be a metallic substrate (e.g., steel, an alloy,
copper, aluminum, and combinations thereof), a polymeric substrate
(e.g., thermoplastic polyolefin), or asphalt.
[0049] After a desired shape is formed from the desired material, a
method may comprise forming tabs on a buttlap region of a shingle.
In some embodiments, tabs may be formed by chiseling, machining, or
otherwise mechanically removing material disposed in intended
spacings between intended tabs of the buttlap region. In some
embodiments, tabs may be formed by manufacturing a shingle in an
appropriate mold that may be shaped with corresponding tab
designs.
[0050] After a desired shape is formed from the desired material, a
method may comprise disposing sealants on a shingle. Sealants may
be disposed on a back buttlap surface and/or a top headlap surface.
Sealants may be formed along a length of the shingle. In some
embodiments, a roofing shingle may comprise sealants on both a back
buttlap surface and a top headlap surface. In some embodiments,
disposing a sealant on a shingle may comprise contacting a surface
of a shingle with a material comprising a sealant and/or a
conditional sealant with a shingle and, optionally, at least
partially curing and/or drying the material. In some embodiments,
contacting a shingle surface and a sealant may comprise forming a
sealant bead on the shingle surface, depositing sealant on the
shingle surface, applying sealant on the shingle surface, injecting
sealant into the surface, and/or forming a pattern of sealant on
the shingle surface along at least a portion of the shingle.
[0051] After a desired shape is formed from the desired material, a
method may comprise disposing release tape on a shingle. Release
tape may be disposed on a back surface and/or a top surface.
Release tape may be formed along a length of the shingle. In some
embodiments, a roofing shingle may comprise release tape on both a
back surface (e.g., a back headlap surface) and a top surface
(e.g., a top headlap surface). In some embodiments, disposing a
release tape on a shingle may comprise adhering a release tape
using an adhesive. In some embodiments, release tape may be
removable prior to installation of a roofing system. In some
embodiments, release tape may be disposed on shingle and removable
prior to installation may not be necessary.
Assembly of Articles
[0052] The present disclosure relates, according to some
embodiments, to assemblies of articles that may be wrapped,
stacked, and/or shipped (e.g., to an installation site). Assemblies
of articles may comprise shingles with dual sealants configured and
arranged to reduce undesired binding or contact of sealant to other
materials. An assembly may comprise a first shingle and a second
shingle, wherein the top surface of the first shingle contacts the
back surface of the second shingle. To avoid premature contact
between mateable sealant strips, however, the second shingle may be
rotated 180.degree. relative to its position upon installation
according to some embodiments. For example, a top buttlap surface
of a first shingle may be adjacent to and/or contact a back headlap
surface of a second shingle. A top headlap surface of a first
shingle may be adjacent to and/or contact a back buttlap surface of
a second shingle. Successive shingles may be stacked in this
alternating pattern, each rotated about 180.degree. relative to the
last. In an alternating configuration, tabs of successive shingles
face opposite directions.
[0053] In some embodiments, a tape strip on the top headlap surface
of a first shingle may be adjacent to and/or contact a sealant
strip on a back buttlap surface of a second shingle. In some
embodiments, a sealant on a top headlap surface of a first shingle
may be positioned to be adjacent to and/or contact a guide strip on
a back surface (e.g., headlap) of a second shingle.
[0054] The present disclosure relates, in some embodiments, to
assemblies of articles (e.g., packages of shingles) that may be
space-efficient and may prevent inadvertent adhering of a sealant
to an undesired surface. Since a first and second sealant, in some
embodiments, may not become adhesive until contact with another
sealant, the assemblies of the present disclosure may prevent
unintended adherence of a sealant to an undesired surface. For
example, positioning a top headlap surface of a first shingle
against a back buttlap surface of a second shingle (e.g., with
oppositely facing tabs) may not expose a first sealant and a second
sealant to one another. Similarly, positioning a top buttlap
surface of a first shingle against a back headlap surface of a
second shingle, may not expose a first sealant and a second sealant
to one another.
Methods of Packing
[0055] The present disclosure relates, according to some
embodiments, to methods of packing articles (e.g., dual sealant
shingles). In some embodiments, a method may comprise providing a
plurality of shingles, wherein each shingle comprises a headlap
region comprising a top headlap surface and a back headlap surface,
and a buttlap region comprising a top buttlap surface and a back
buttlap surface. A method may comprise providing a first sealant on
a top headlap surface of a shingle and providing a second sealant
on a back headlap surface of the shingle. A method may comprise, in
some embodiments, positioning a second shingle over a first shingle
and contacting the back surface of the second shingle to the top
surface of the first shingle. For example, a method may include
positioning a first and/or a second shingle so a top headlap
surface of the first shingle is adjacent to and/or contacts a back
buttlap surface of the second shingle, a top buttlap surface of the
first shingle is adjacent to and/or contacts back headlap surface
of the second shingle, tabs of the first and second shingle face
away from each other, the upper edge of the first shingle is
aligned with and adjacent to the lower edge of the second shingle,
and/or the upper edge of the second shingle is aligned with and
adjacent to the lower edge of the first shingle. A packing method
may comprise contacting a top surface of a first shingle with a
back surface of a second shingle. The headlap of the first shingle
may contact the buttlap of the second shingle. The buttlap of the
first shingle may contact the headlap of the second shingle. Tabs
of the first and second shingles may be oppositely and outwardly
positioned. For example, tabs (or dragon teeth) of each successive
shingle may be positioned along opposite long edges in a stack of
shingles. In some embodiments, positioning may include moving a
first shingle, moving a second shingle, or moving both a first
shingle and a second shingle to a desired position. For example, a
method may include positioning a loose second shingle over a packed
first shingle.
[0056] In some embodiments, a method may include positioning first
and second shingles so a tape on a top headlap surface of a first
shingle may be adjacent to and/or contact a sealant on a back
buttlap surface of a second shingle. In some embodiments, a sealant
on a top headlap surface of a first shingle may be adjacent to
and/or contact a tape on a back buttlap region of a second
shingle.
Specific Example Embodiments
[0057] Specific example embodiments of a shingle with dual sealants
are illustrated in FIGS. 1-7. FIG. 1A illustrates a top view of
shingle 101 according to an example embodiment of the disclosure.
FIG. 1B illustrates a back view of shingle 101 shown in FIG. 1A.
Shingle 101 may comprise headlap region 102 and buttlap region 104.
Headlap region 102 may comprise top headlap surface 106 and
opposite-facing back headlap surface 108. Buttlap region 104 may
comprise top buttlap surface 110 and oppositely facing back buttlap
surface 112. As seen in FIG. 1A, top headlap surface 106 may
include sealant 111 and tape 114. As seen in FIG. 1B, back headlap
surface 108 may include tape 116. Back buttlap surface 112 may
comprise sealant 113 positioned along the lower edges of tabs 118.
As seen in FIG. 1A and FIG. 1B, in some embodiments, sealant 111
and sealant 113 may have substantially stripe-shaped geometries. In
some embodiments, sealant 111 and sealant 113 may have the same
shape and size.
[0058] Buttlap region 104 of shingle 101 has three tabs 118 that
extend from headlap region 102. Tabs 118 are interspersed from one
another by spaces 120. Shingle 101 may have a different number of
tabs 118 in a buttlap region. Furthermore, each of tabs 118 may
have any particular shape or size needed to suit aesthetical or
functional goals. For example, a tab shape may be substantially
trapezoidal to achieve a dragon tooth shingle. Similarly, each of
spacings 120 may have any particular shape or size needed to suit
aesthetical or functional goals. Variations may be made to a shape,
size, and number of tabs 118 and spacings 120 to buttlap region 104
of shingle 101 as desired or required.
[0059] FIG. 2A and FIG. 2B illustrate a back perspective view and
profile view, respectively, of shingle system 200 according to
embodiments of the disclosure. FIG. 2A and FIG. 2B illustrate how
two shingles, shingle 201 and shingle 301, may be aligned to form
roofing system 200. Shingle 201 may have back surface 207 and top
surface 205. Similarly, shingle 301 may have back surface 307 and
top surface 305. Shingle 201 may have sealant 213 on back surface
207. Shingle 301 may have sealant 311 on top surface 305. FIG. 2A
illustrates a back perspective view of how sealant 213 and sealant
311 may be aligned prior to contact. FIG. 2B illustrates a profile
view of how sealant 213 and sealant 311 may be aligned prior to
contact. In some embodiments, sealant 213 and sealant 311 may not
become adhesive until contact or mating with one another. When
sealant 213 and sealant 311 are aligned properly, they may be
affixed to one another through direct contact to form a strong
adhesive bond (e.g., about as strong as the bond between 213 and
201, about as strong as the bond between 311 and 301). In some
embodiments, sealant 213 and sealant 311 may each have a release
tape (not pictured) prior to installation. Release tapes may be
applied during a manufacturing process of shingles 201, 301.
Release tapes may reduce (e.g., prevent) unintended exposure of an
adhesive to undesired materials such as another shingle, a wrong
surface or region of a target shingle, dust and specks, and
others.
[0060] Various features present on shingles may be included on
shingle 201 and shingle 301 as seen in FIG. 2A and FIG. 2B. For
example, shingles 201 and 301 may be solid as shown in FIG. 2A and
FIG. 2B or they may include tabs of any desired size, spacing, or
shape. Shingle 201 may lack an adhesive strip on its top as shown
(e.g., where it is to be the uppermost or last shingle to be
applied to a sealant substrate) as shown or it may include a
sealant strip. Also, shingle 301 may lack a sealant strip on its
back as shown (e.g., where it is to be applied directly to a
roofing substrate) as shown or it may include a sealant strip.
[0061] FIGS. 3A-3B illustrate shingle system 400 according to some
embodiments of the disclosure. FIG. 3A illustrates a top
perspective view of shingle system 400. As seen in FIG. 3A, shingle
401 and shingle 501 may be positioned (e.g., laterally and/or
vertically offset as desired) for assembly on a roof. In FIG. 3A
both shingle 401 and shingle 501 are viewed from the top. Shingle
401 may have headlap region 402 and buttlap region 404. From the
perspective of FIG. 3A, top headlap surface 406 and top buttlap
surface 408 are visible. Buttlap region 404 may comprise a
plurality of tabs 418 that may be defined, in part, by spacings
420. Top headlap surface 406 may have sealant 411 affixed to it.
Shingle 401 may also have another sealant (e.g., sealant 413) on
its back buttlap region, which is not be visible from the
perspective of FIG. 3A. Shingle 501 may have headlap region 502 and
buttlap region 504. From the perspective of FIG. 3A, top headlap
surface 506 and top buttlap surface 508 are visible. Buttlap region
504 may comprise a plurality of tabs 518 that may be defined, in
part, by spacings 520. Top headlap surface 506 may have sealant 511
affixed to it. In some embodiments, a sealant (e.g., sealant 413)
on a back buttlap region of shingle 401 may align with sealant 511
on top headlap surface 506 of shingle 501. Two sealants may
initially be factory-applied to the respective shingles on which
they are disposed. This may allow each of the sealants to form a
strong bond with the shingle to which they are applied. Each of two
sealants may not become adhesive until they are in contact with one
another. For example, they may be adhesive when factory-applied to
a shingle (e.g., so it may bind the shingle to which it is
applied), but thereafter, the outer surface may have little or no
"stickiness" unless/until contact is made with another sealant.
Contact may be achieved through alignment (e.g., approximate
alignment, substantial alignment, exact alignment) of the two
sealants, which may have substantially striped-shaped geometries.
In some embodiments, each sealant's size and shape may be
independently selected. For example, any two sealants may have the
same size and the same shape, the same shape by different sizes,
the same sizes, but different shapes, or different sizes and
different shapes.
[0062] FIG. 3A depicts the positions of only two shingles.
Specifically, shingle 401 is vertically offset to align sealants
413 and 511 and laterally offset such that spacings 420 overlay
tabs 518. Additional shingles may be positioned in like manner such
that a number of shingles are used to form of roof covering. For
example, a third shingle may be positioned over shingle 401, such
that a sealant on a back buttlap of a third shingle may be aligned
with and affixed to sealant 411 on top headlap surface 406 of
shingle 401. By arranging each shingle such that it overlaps at
least a portion of a shingle immediately below, a roofing system
may be established that substantially covers 100% of a substrate on
a structure.
[0063] FIG. 3B illustrates a profile view of shingle system 400
according to embodiments of the present disclosure. As shown,
buttlap 404 and a lower portion of headlap 402 may contact headlap
502-surface 412 and a lower portion of surface 408 may contact
surface 506. Back buttlap surface 412 contacts top headlap surface
506 below tape 514. Shingle 401 and shingle 501 may be positioned
such that sealant 413 on back surface 407 of shingle 401 may be
aligned with sealant 511 on top surface 505 of shingle 501 as
shown. A roof substrate, if shown, would appear to the right of
shingle 501. Shingle 401 and shingle 501 may each comprise one
layer as shown. However, shingles according to some embodiments of
the present disclosure may each have one layer or a plurality of
layers.
[0064] FIG. 4A and FIG. 4B respectively illustrate top and back
surfaces of dragon's tooth shingle 601 according to embodiments of
the disclosure. As seen in FIG. 4A, some embodiments of the present
disclosure may relate to shingles with a dragon's tooth design.
Shingle 601 comprises first layer 622 and second layer 624. Shingle
601 in FIG. 4A may comprise buttlap region 604 with top layer 622
and bottom layer 624. In some embodiments, top layer 622 may
comprise tabs 618 with substantially trapezoidal geometries (e.g.,
a dragon's tooth design) and corresponding cut-outs 620. FIG. 4A
and FIG. 4B are given by way of example that the present disclosure
is not limited to any particular shingle structure, as shingle 601
may comprise headlap region 602 having top headlap surface 606 and
back headlap surface 608; and buttlap region 604 having top buttlap
surface 610 and back buttlap surface 612. Top headlap surface 606
may comprise sealant 611 and tape 614 positioned along opposite
edges. Back headlap surface 608 may comprise tape 616 positioned
along the lower edge of 608. Back buttlap surface 612 may comprise
sealant 613 positioned along lower edge of shingle 601. As shown in
FIG. 4B and FIG. 4C, bottom layer 624 may extend from the lower
edge of shingle 601 across buttlap 604 and partially into headlap
602 to a point adjacent to tape 616.
[0065] FIG. 4C illustrates a profile view of system 600 according
to embodiments of the present disclosure. As shown, system 600
comprises shingles 601 and 601'. Sealant 613 of shingle 601
contacts sealant 611' in successive shingle 601' as shown. Tape 616
on back headlap surface 608 contacts tape 614'. The back surface of
layer 624 (e.g., surface 612) contacts the top headlap surface of
the successive shingle below tape 614'. A roof substrate, if shown,
would appear to the right of system 600. Each of a plurality of
layers within a shingle may comprise a different material and may
be of a different shape, size, or thickness. Variations in these
attributes may help achieve aesthetic and/or functional goals such
as thinner shingles or lighter shingles, according to some
embodiments.
[0066] FIG. 5A illustrates a profile view of shingle system 700
according to embodiments of methods for packaging assemblies of
shingles according to the disclosure. As seen in FIG. 5A, shingle
701 and shingle 801 may be positioned such that top headlap surface
806 of shingle 801 substantially contacts back buttlap surface 712
of shingle 701. Two shingles 701, 801 may be positioned such that
top buttlap surface 810 of shingle 801 substantially contacts back
headlap surface 708 of shingle 701. Upper edge 730 of shingle 700
may be adjacent to, may be aligned with, and/or may contact lower
edge 831 of shingle 800. Upper edge 830 of shingle 801 may be
adjacent to, may be aligned with, and/or may contact lower edge 731
of shingle 701. Pluralities of shingles may be arranged in the
above fashion following the described method. Accordingly,
pluralities of shingles may be arranged as an assembly that may be
convenient for packing and packaging of the shingles. In some
embodiments, release tapes may contact one or more of sealant 711,
sealant 713, sealant 811, and/or sealant 813 (e.g., sealant 713 and
sealant 811).
[0067] FIG. 5B illustrates an exploded view of one portion of the
profile view of FIG. 5A. As seen in FIG. 5B, shingle 701 and
shingle 801 may be positioned such that sealant 713, disposed on
back buttlap surface 812, contacts tape 814 on top headlap surface
806. Sealant 713 may comprise material that may not become adhesive
until contact or mating with a material of like quality.
Accordingly, sealant 713 may not become adhesive when overlapping
with tape 814.
[0068] FIG. 5C illustrates an exploded view of one portion of the
profile view of FIG. 5A. As seen in FIG. 5C, shingle 701 and
shingle 801 may be positioned such that sealant 811 on top headlap
surface 806 contacts or rests against tape 716 on back headlap
surface 708 (adjacent to back buttlap surface 712). Sealant 711 may
similarly contact or rest against a tape on a successive shingle
(not shown). Tape 816 on back headlap surface 808 (adjacent to back
buttlap surface 812) may, in turn, contact a sealant on a
successive shingle. Sealant 811 may not become adhesive until
contact or mating with a material of like quality (e.g., another
conditional sealant). Accordingly, sealant 811 may not become
adhesive when contacting tape 716. In some embodiments, sealant 716
may substantially overlap or rest against a top surface of another
single.
[0069] As seen in FIG. 5A, FIG. 5B, and FIG. 5C, shingles according
to embodiments of the present disclosure may each comprise one
layer. However, shingles of the present disclosure may also
comprise a plurality of layers, and some embodiments may be used in
the methods for packaging assembles of shingles according to the
present disclosure. For example, FIG. 6A and FIG. 6B illustrate
profile views of shingle system 900 wherein shingles 901 and 1001
may comprise a plurality of layers.
[0070] FIG. 6 illustrated assembly 900 in which shingles 901 and
1001 are positioned to contact one another substantially without
adhering to one another (e.g., for shipping). As seen in FIG. 6,
shingle 901 may comprise upper layer 922 and lower layer 924 and
shingle 1001 may comprise upper layer 1022 and lower layer 1024.
Headlap 902 may comprise oppositely facing top surface 906 and back
surface 908. Buttlap 904 may comprise oppositely facing top surface
910 and back surface 912. Buttlap region 904 may comprise a portion
of upper layer 922 and a portion of lower layer 924. Similarly,
headlap 1002 may comprise oppositely facing top surface 1006 and
back surface 1008. Buttlap 1004 may comprise oppositely facing top
surface 1010 and back surface 1012. Buttlap region 1004 may
comprise a portion of upper layer 1022 and a portion of lower layer
1024. Tape 914 and tape may be affixed adjacent to upper edges 930
and 1030, respectively. Tape 916 may be affixed to headlap surface
908 adjacent to the upper edge of layer 924. Tape 1016 may be
affixed to headlap surface 1008 adjacent to the upper edge of layer
1024. Sealant strip 911 and sealant strip 1011 may be affixed to
layers 922 and 1022 along the approximate middle of shingles 901
and 1001, respectively. Sealant strip 913 and sealant strip 1013
may be affixed to layers 924 and 1024 adjacent lower edges 931 and
1031, respectively.
[0071] Methods of packaging assemblies of shingles according to the
present disclosure may comprise positioning shingle 901 and shingle
1001 such that top headlap 1006 abuts back buttlap 912, back
headlap 908 abuts top headlap 1010, upper edge 930 of shingle 901
may be adjacent to, may be aligned with, and/or may contact lower
edge 1031 of shingle 1001, upper edge 1030 of shingle 1001 may be
adjacent to, may be aligned with, and/or may contact lower edge 930
of shingle 901, and/or layer 924 and layer 1024 do not
substantially overlap. Sealant 911 and/or sealant 1013 may not
become adhesive until contact or mating with another sealant (e.g.,
each other). Sealant 913 and/or sealant 1011 may not become
adhesive until contact or mating with another sealant (e.g., each
other). Accordingly, for example, sealant 913 may not become
adhesive when contacting tape 1014 on layer 1022 as shown. Sealant
1011 may not become adhesive when contacting tape 916 on layer 922.
In some embodiments, assembly 900 may include a third shingle, for
example, to the right of shingle 1001. A third shingle may be
oriented like shingle 901. By stacking pluralities of shingles
according to the presently described method, an assembly of
shingles for packaging may be formed.
[0072] FIG. 7 illustrates a top view of two shingles aligned
according to an embodiment of the disclosure. As shown, shingle
system 1100 may comprise shingles 1101, 1201 disposed against one
another. In some embodiments, shingle system 1100 may be operable
as a roofing system for cladding a structure. In some embodiments,
shingle 1101 and shingle 1201 may be positioned such that there may
be a vertical offset and a lateral offset relative to each other.
For example, shingle 1101, which may be disposed above shingle
1201, may not be aligned such that the length of shingle 1101 may
be disposed directly over the length of shingle 1201. Instead, the
length of shingle 1101 may be staggered or offset laterally from
the length of shingle 1201. As shown here, shingle 1101 is shifted
laterally to the left of shingle 1201 such that spacings 1120 are
aligned with the middle of tabs 1218. Shingle 1101 is vertically
offset such that sealant 1113 (not visible in this view) on the
back of tabs 1118 aligns with and contacts sealant 1211. In some
embodiments, pluralities of shingles may be arranged in the
presently described staggered fashion as part of a roofing system
on a structure. A staggered arrangement or lateral offset between
shingles may advantageously promote stability between shingles of a
roofing system and may serve to promote various other aesthetical
or functional objectives.
[0073] As will be understood by those skilled in the art who have
the benefit of the instant disclosure, other equivalent or
alternative articles, systems, and methods for shingles with dual
sealants may be envisioned without departing from the description
contained herein. Accordingly, the manner of carrying out the
disclosure as shown and described is to be construed as
illustrative only.
[0074] One of ordinary skill in the art having the benefit of the
present disclosure may make various changes in the shape, size,
number, materials, and/or arrangement of parts without departing
from the scope of the instant disclosure. For example, the position
and number of sealants or plurality of areas of sealants may be
varied. In addition, the size of the articles and/or systems may be
scaled up or down to suit the needs of a particular use or roofing
structure. Each disclosed method and method step may be performed
in association with any other disclosed method or method step and
in any order according to some embodiments. Where the verb "may"
appears, it is intended to convey an optional and/or permissive
condition, but its use is not intended to suggest any lack of
operability unless otherwise indicated. One of ordinary skill in
the art having the benefit of the present disclosure may make
various changes in methods of use and methods of manufacturing the
articles and/or systems of the disclosure.
[0075] Also, where ranges have been provided, the disclosed
endpoints may be treated as exact and/or approximations as desired
or demanded by the particular embodiment. Where the endpoints are
approximate, the degree of flexibility may vary in proportion to
the order of magnitude of the range. For example, on one hand, a
range endpoint of about 50 in the context of a range of about 5 to
about 50 may include 50.5, but not 52.5 or 55 and, on the other
hand, a range endpoint of about 50 in the context of a range of
about 0.5 to about 50 may include 55, but not 60 or 75. In
addition, it may be desirable, in some embodiments, to mix and
match range endpoints. Also, in some embodiments, each figure
disclosed (e.g., in one or more of the examples, tables, and/or
drawings) may form the basis of a range (e.g., depicted
value+/-about 10%, depicted value+/-about 50%, depicted
value+/-about 100%) and/or a range endpoint. With respect to the
former, a value of 50 depicted in an example, table, and/or drawing
may form the basis of a range of, for example, about 45 to about
55, about 25 to about 100, and/or about 0 to about 100.
[0076] All or a portion of a device and/or system for articles,
systems, and methods for shingles with dual sealants may be
configured and arranged to be disposable, serviceable,
interchangeable, and/or replaceable. These equivalents and
alternatives along with obvious changes and modifications are
intended to be included within the scope of the present disclosure.
Accordingly, the foregoing disclosure is intended to be
illustrative, but not limiting, of the scope of the disclosure as
illustrated by the appended claims.
[0077] The title, abstract, background, and headings are provided
in compliance with regulations and/or for the convenience of the
reader. They include no admissions as to the scope and content of
prior art and no limitations applicable to all disclosed
embodiments.
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