U.S. patent application number 16/750620 was filed with the patent office on 2020-08-06 for shingle with enhanced bonding.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Kevin A. Click, Lawrence J. Grubka.
Application Number | 20200248456 16/750620 |
Document ID | / |
Family ID | 1000004658538 |
Filed Date | 2020-08-06 |
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United States Patent
Application |
20200248456 |
Kind Code |
A1 |
Click; Kevin A. ; et
al. |
August 6, 2020 |
SHINGLE WITH ENHANCED BONDING
Abstract
A shingle which includes a substrate, granules deposited on the
substrate, a first material strip applied to the top of the
substrate, a second material strip applied to the bottom of the
substrate, and an adhesive applied to the second material strip.
The second material strip is positioned along an edge of the
substrate such that when a shingle is applied to a roof overlaying
an existing shingle, the adhesive adheres the second material strip
of the overlaying shingle to the first material strip of the
existing shingle. The second material strip is applied to the
bottom of the substrate prior particles being applied to the bottom
surface of the substrate.
Inventors: |
Click; Kevin A.; (Columbus,
OH) ; Grubka; Lawrence J.; (New Albany, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
1000004658538 |
Appl. No.: |
16/750620 |
Filed: |
January 23, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62799103 |
Jan 31, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 2001/005 20130101;
E04D 2001/3435 20130101; E04D 1/34 20130101; E04D 1/26 20130101;
E04D 2001/3491 20130101; E04D 2001/3447 20130101; E04D 1/20
20130101 |
International
Class: |
E04D 1/34 20060101
E04D001/34; E04D 1/26 20060101 E04D001/26; E04D 1/20 20060101
E04D001/20 |
Claims
1. A shingle comprising: an asphalt coated substrate; a first
material strip applied on a top side of the substrate; granules
disposed on a top side of the substrate which comprises the first
material strip; a second material strip applied on a bottom side of
the substrate and closer to a first edge than any other edge; and
an adhesive applied to an exposed face of the second material
strip.
2. The shingle of claim 1, further comprising a third material
strip applied on the bottom side of the substrate and closer to a
second edge than any other edge, wherein the second edge is
opposite and parallel to the first edge.
3. The shingle of claim 2, wherein the third material strip
comprises of a material to which the adhesive does not adhere.
4. The shingle of claim 2, wherein the second material strip is
located substantially the same distance from the first edge as the
third material strip is located from the second edge.
5. The shingle of claim 1, wherein the second material strip is
formed from a material selected from the group consisting of:
polyester, polypropylene, polyethylene, polyamide, polystyrene,
polyethylene terephthalate, polyacrylonitrile, aramid, and
combinations thereof.
6. The shingle of claim 2, wherein the first material strip is
located equidistant from the first edge and the second edge.
7. The shingle of claim 6, wherein the second material strip is
positioned such that when the shingle is installed on a roof to
partially cover a previously installed shingle, the second material
strip is operable to substantially overlap a first material strip
of the previously installed shingle.
8. The shingle of claim 7, wherein the second material strip has a
thickness operable to cause the adhesive to contact the first
material strip.
9. A shingle comprising: an overlay comprising: an asphalt coated
overlay substrate; a first material strip applied to a top surface
of the overlay substrate; and granules disposed on the top surface
of the overlay substrate; and an underlay comprising: an asphalt
coated underlay substrate; granules disposed on a top surface of
the underlay substrate; a second material strip applied on a bottom
side of the underlay substrate closer to a first edge than any
other edge of the underlay substrate; and an adhesive adhered to
the second material strip.
10. The shingle of claim 9, further comprising a third material
strip applied on the bottom side of the overlay substrate and
closer to a second edge of the overlay substrate than any other
edge of the overlay substrate, wherein the second edge of the
overlay substrate is opposite and parallel to a first edge of the
overlay substrate.
11. The shingle of claim 10, wherein the third material strip
comprises a material to which the adhesive does not adhere.
12. The shingle of claim 10, wherein the third material strip is
comprised of a material to which the adhesive does not adhere.
13. The shingle of claim 10, wherein the second material strip is
located substantially the same distance from the first edge as the
third material strip is located from the second edge.
14. The shingle of claim 10, wherein the second material strip is
formed from a material selected from the group consisting of:
polyester, polypropylene, polyethylene, polyamide, polystyrene,
polyethylene terephthalate, polyacrylonitrile, aramid, and
combinations thereof.
15. The shingle of claim 9, wherein the first material strip is
located at point mid-way between the first edge and a second
edge.
16. The shingle of claim 9, wherein the second material strip is
located such that when the shingle is installed on roof and
partially covering a previously installed shingle, the second
material strip substantially overlaps a first material strip of the
previously installed shingle.
17. The shingle of claim 16, wherein the second material strip is
formed from a material with a thickness that causes the adhesive to
make contact with the first material strip.
18. A method of stacking shingles comprising: placing a first
shingle in contact with a second shingle, the first shingle and the
second shingle each having an upper face coated with granules, a
lower face having a first material and a second material, and an
adhesive applied to the second material; arranging the first and
second shingles such that the first shingle and the second shingle
are longitudinally aligned and the first shingle substantially
covers the second shingle; orienting the first shingle such that
its lower face is in contact with the lower face of the second
shingle, and further orienting the first shingle so that its first
material is in contact with the adhesive of the second material of
the second shingle.
19. The method of claim 18, further comprising arranging a third
and fourth shingle in the manner of the first and second shingle;
and placing the upper face of either the third or fourth shingle in
contact with and longitudinally aligned with the upper face of
either the first or second shingle.
20. The method of claim 19, wherein the second material strip is
formed from materials selected from the group consisting of:
polyester, polypropylene, polyethylene, polyamide, polystyrene,
polyethylene terephthalate, polyacrylonitrile, aramid, and
combinations thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and all benefit of U.S.
Provisional Patent Application Ser. No. 62/799,103, filed on Jan.
31, 2019, for Shingle With Enhanced Bonding, the entire disclosure
of which is fully incorporated herein by reference.
FIELD
[0002] The present invention relates generally to shingles for
protecting a roof of a structure, and more particularly, to
shingles having improved bonding between an upper and lower
shingle.
BACKGROUND
[0003] Many structures have pitched, shingled roofs, to prevent
water, e.g., rain water, from entering the structures by causing
the water to pass over the shingles and shed off the roofs. A
pitched, shingled roof has a pitched deck, such as a plurality of
plywood sheets, with a plurality of shingles attached thereto.
[0004] When viewed individually, each shingle has an upper portion
(i.e., a headlap portion) and a lower portion (i.e., an exposure
portion) wherein the exposure portion is exposed to the
environment. The shingles are typically attached to the deck in
rows known as courses wherein the exposure portion of an upper
course of shingles overlaps the headlap portion of an adjacent
lower course of shingles. For example, a first course of shingles
may be attached to the deck nearest the lowest point of the roof,
i.e., the eave portion of the roof. A second course of shingles may
then be attached to the deck slightly higher on the roof than the
first course. The shingles are placed so that the exposure portion
of the second course of shingles overlaps the headlap portion of
the first course of shingles. This overlapping continues with
successive rows of shingles to the highest point on the area of the
roof, i.e., the hip or the ridge.
[0005] Hip and ridge shingles are applied along a hip or ridge of a
roof (i.e., transverse to the courses of shingles). These hip and
ridge shingles span a gap or intersection between courses of
shingles of roof planes that meet at a hip or ridge. These hip and
ridge shingles are typically applied along the hip or ridge in a
similar fashion, with the exposure portion of one hip and ridge
shingle covering the headlap portion of an adjacent shingle on the
hip or ridge. Thus, only the exposure portion of the shingles are
exposed to the environment. This overlapping of the shingles causes
water to pass from shingles on higher courses to shingles on the
next lowest course of shingles without contacting the deck.
Accordingly, water passes from shingle to shingle and off the roof
without contacting the deck or entering the structure.
[0006] Attaching the shingles to the roof is typically achieved
using nails, staples, or other fastening devices that pass through
the shingles and into or through the deck. The fastening devices
are typically placed through the headlap portion of the shingles so
that they are overlapped by shingles in an adjacent higher course
as described above. This placement of the fasteners prevents water
from entering the structure through holes caused by the
fasteners.
[0007] To secure the lower portion of shingles from a higher course
to the headlap portion of shingles in a lower course, an adhesive
is provided on the back of the exposed portion that becomes affixed
to the headlap portion of the shingles in the course immediately
lower (below) the shingle with the adhesive.
SUMMARY
[0008] The present application discloses several embodiments of
shingles having an adhesive applied to an adhesion promoting
substance located on a bottom surface of the shingle. Such an
adhesion promoting substance could be a tape, a woven strip, a
non-woven strip, fibers, or coatings sprayed or otherwise applied,
or similar substances. The adhesion promoting substance will be
referred to herein as an adhesion promoting strip, but such a
reference should not be construed as limiting the substance to only
a strip. In exemplary embodiment a shingle comprises an asphalt
coated substrate, a first material strip applied on a top side of
the substrate, granules disposed on a top side of the substrate
after the first material strip is applied, a second material strip
applied on a bottom side of the substrate and adjacent to a first
edge, and an adhesive adhered to an exposed face of the second
material strip.
[0009] In another exemplary embodiment, a shingle comprises an
overlay comprising an asphalt coated overlay substrate, a first
material strip applied to a top side of the overlay substrate, and
granules disposed on a top side of the overlay substrate; and an
underlay comprising an asphalt coated underlay substrate, granules
disposed on a top side of the underlay substrate, a second material
strip applied on a bottom side of the underlay substrate along an
edge of the underlay substrate, and an adhesive adhered to the
second material strip.
[0010] In another exemplary embodiment, a method of stacking
shingles comprises placing a first shingle in contact with a second
shingle, the first shingle and the second shingle having an upper
face coated with granules and a lower face having a first material
and a second material, and an adhesive applied to the second
material; arranging the first and second shingles such that the
first shingle and the second shingle are longitudinally aligned and
the first shingle substantially covers the second shingle;
orienting the first shingle such that its lower face is in contact
with the lower face of the second shingle; and further orienting
the first shingle so that its first material is in contact with the
adhesive applied to the second material of the second shingle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features and advantages of the present
invention will become better understood with regard to the
following description and accompanying drawings in which:
[0012] FIG. 1 is a partial side view of a known embodiment of a
first shingle which comprises an adhesive on a bottom side of a
substrate;
[0013] FIG. 2 is a partial side view of the first shingle of FIG. 1
adhered to a second shingle according to a known embodiment;
[0014] FIG. 3 is a partial side view of the first and second
shingle of FIG. 2 in which the adhesive attachment of the shingles
has failed;
[0015] FIG. 4 is a partial side view of a known embodiment of a
first shingle which comprises a first strip positioned to be
adhered to a second shingle which comprises an adhesive applied to
its bottom surface;
[0016] FIG. 5 is a partial side view of the first and second
shingles of FIG. 4 after they have been attached;
[0017] FIG. 6 is a partial side view of the first and second
shingles of FIG. 5 in which the adhesive attachment of the shingles
has failed;
[0018] FIG. 7 is a partial side view of a first shingle which
comprises a first strip positioned to be adhered to a second
shingle which according to an exemplary embodiment comprises an
adhesive applied to a second strip which has been applied to a
bottom surface of the second shingle;
[0019] FIG. 8 is a partial side view of the first and second
shingles of FIG. 7 after they have been attached;
[0020] FIG. 9 is a partial side view of the first and second
shingles of FIG. 8 in which the adhesive attachment of the shingles
has failed;
[0021] FIG. 10 is a partial side view of a known embodiment of a
first shingle which comprises a first strip positioned in contact
with a second shingle where an adhesive applied to a bottom surface
of the second shingle fails to completely contact the first
strip;
[0022] FIG. 11 is a partial side view of a first shingle which
comprises a first strip positioned to be adhered to a second
shingle which according to an exemplary embodiment comprises an
adhesive applied to a second strip which has been applied to a
bottom surface of the second shingle;
[0023] FIG. 12 is a partial side view of a first shingle which
comprises a first strip positioned in contact with a second shingle
according to an exemplary embodiment where the thickness of a
second strip causes an adhesive applied to a bottom surface of the
second shingle to contact the first strip;
[0024] FIG. 13 is a side elevation view of a shingle structure
according to an exemplary embodiment;
[0025] FIG. 14 is a top plan view of the shingle of FIG. 13;
[0026] FIG. 15 is a bottom plan view of the shingle of FIG. 13;
[0027] FIG. 16 is a perspective view of first and second shingles
corresponding to the embodiment illustrated in FIG. 13, wherein the
shingles are aligned as they would be prior to installation on a
roof;
[0028] FIG. 17 is a perspective view of the first and second
shingles of FIG. 16 positioned in contact with each other as
installed on a roof;
[0029] FIG. 18 is a side elevation view of a shingle according to
an alternative exemplary embodiment;
[0030] FIG. 19 is a top plan view of the shingle of FIG. 18;
[0031] FIG. 20 is a bottom plan view of the shingle of FIG. 18;
[0032] FIG. 21 is a perspective view of first and second shingles
corresponding to the embodiment illustrated in FIG. 18, wherein the
shingles are aligned as they would be prior to installation on a
roof;
[0033] FIG. 22 is a perspective view of the first and second
shingles of FIG. 21 positioned in contact with each other as
installed on a roof;
[0034] FIG. 23 is a side elevation view of a shingle according to
an alternative exemplary embodiment;
[0035] FIG. 24 is a top plan view of the shingle of FIG. 23;
[0036] FIG. 25 is a bottom plan view of the shingle of FIG. 23;
[0037] FIG. 26 is a perspective view of first and second shingles
corresponding to the embodiment illustrated in FIG. 23, wherein the
shingles are aligned as they would be prior to installation on a
roof;
[0038] FIG. 27 is a perspective view of the first and second
shingles of FIG. 26 positioned in contact with each other as
installed on a roof;
[0039] FIG. 28 is a diagram of an exemplary embodiment of a
production process which produces shingles according to an
exemplary embodiment;
[0040] FIG. 29 is a side view of packaged shingles stacked
according to known methods;
[0041] FIG. 30 is a side view of a known embodiment of a first
shingle stacked with a second shingle prior to installation on a
roof; and
[0042] FIGS. 31A-31C are side views illustrating stacking of
shingles according to an exemplary embodiment for shipment and
storage prior to installation on a roof.
DETAILED DESCRIPTION
[0043] Prior to discussing the various embodiments, a review of the
definitions of some exemplary terms used throughout the disclosure
is appropriate. Both singular and plural forms of all terms fall
within each meaning.
[0044] As described herein, when one or more components are
described as being connected, joined, affixed, coupled, attached,
or otherwise interconnected, such interconnection may be direct as
between the components or may be indirect such as through the use
of one or more intermediary components. As described herein,
reference to a "member," "component," or "portion" shall not be
limited to a single structural member, component, or element but
can include an assembly of components, members or elements. Also,
as described herein, the terms "substantially" and "about" are
defined as at least close to (and includes) a given value or state
(preferably within 10% of, more preferably within 1% of, and most
preferably within 0.1% of).
[0045] Various shingles are disclosed herein. Certain exemplary
embodiments have an overlay substrate which is positioned on an
underlay substrate to provide a shingle assembly that appears
thicker, may be more durable, and provides a greater architectural
appeal. Other exemplary embodiments have a single substrate. These
exemplary embodiments are provided with an adhesive that secures a
first shingle to a second shingle positioned below the first
shingle when installed on a roof structure.
[0046] FIG. 1 illustrates a side view of a known shingle 100. As
shown, the shingle 100 comprises a substrate 102, an upper coating
of asphalt 104 and a lower coating of asphalt 106. A coating of
granules 108 is applied to the upper surface of the substrate 102
and the upper coating of asphalt 104. In order to prevent the
shingles from adhering to each other during storage as the result
of the lower coating of asphalt, a coating of particles 110 is
applied to the shingle. This coating of particles 110 is not
necessarily for appearance or weather resistance and as a result,
this coating is often sand, or other material that may be less
costly than the granules 108 applied to the upper surface of the
substrate 102 during the manufacturing process.
[0047] As illustrated, an adhesive 112 is applied to the lower
surface of the shingle and in the illustrated example, becomes
attached to the coating of particles 110. FIG. 2 illustrates the
shingle 100 of FIG. 1 after it is placed into contact with a second
shingle 200. Of particular note, the adhesive 112 is contacting the
coating of particles 110 of the first shingle 100 and the granules
208 of the second shingle 200. As was described earlier herein,
shingles are subject to environmental conditions including wind.
Strong winds may cause the shingle 100 to be pulled away from the
second shingle 200 which can result in loosening or loss of
shingles from a roof. Such conditions are undesirable and can
result in roof leaks.
[0048] FIG. 3 illustrates a possible result when known embodiments
are subject to strong winds. As illustrated, the first shingle 100
is pulled away from a second shingle 200. In such circumstances,
the bond between the granules 208 of the second shingle 200 and the
and the upper coating of asphalt 204 may fail, resulting in the
upper shingle 100 becoming detached from the lower shingle 200. In
the example shingles illustrated by FIGS. 1-3, the failure mode is
a portion 302 of the roofing granules delaminating or pulling off
of the asphalt coated substrate 304 of the shingle on the lower
shingle 200.
[0049] FIG. 4 illustrates another example of known shingles in
which an upper shingle 402 is in position for application to a
lower shingle 404. As illustrated, the upper shingle 402 comprises
a substrate 406, a lower coating of asphalt 408, a coating of
particles 410 on the lower surface of the upper shingle 402, and an
adhesive 412. In the illustrated embodiment, the adhesive 412 is
positioned above a nailing reinforcement material 414 that is
bonded directly to an upper asphalt coating 416 of the lower
shingle 404. FIG. 5 illustrates the upper shingle 402 and lower
shingle 404 of FIG. 4 after they have been placed in contact as
would be the case if they were installed on a roof surface.
[0050] As illustrated in FIG. 5, positioning the upper shingle 402
such that the adhesive 412 becomes adhered to the nailing
reinforcement material 414 of the lower shingle 404. This may
improve the bond between the adhesive 412 and the lower shingle 404
in some installations. However, as illustrated in FIG. 6, wind or
other factors can cause the upper shingle 402 to pull away from the
lower shingle 404, resulting in a failure between the lower coating
of asphalt 408 and the particles 410 applied to the lower surface
of the upper shingle 402. In the example illustrated by FIGS. 4-6,
the failure mode is a portion of particles 602 delaminating or
pulling off of the lower coating of asphalt 408 of the upper
shingle 402.
[0051] FIG. 7 illustrates an exemplary embodiment in which a bond
enhancing material 706 is applied to the lower coating of asphalt
708 of the upper shingle 702.
[0052] In some exemplary embodiments, for a large sample (20, 40,
75, 100 or more) of tested shingles, the majority of the debonding
failures results from failure of the adhesive material itself. In a
minority of the tested shingles, the debonding or failure mode
comprises the adhesive delaminating from the reinforcement material
714 or the bond enhancing material 706. In other exemplary
embodiments, the majority of the debonding failures is not failure
of the adhesive material itself, but the bond strength is increased
compared to the bond strength of two shingles with an adhesive that
bonds a reinforcement material 714 of one shingle to coating of
particles 716 of the other shingle and/or compared to the bond
strength of two shingles with an adhesive that bonds granules of
one shingle to particles of another shingle.
[0053] FIG. 8 illustrates the upper shingle 702 and lower shingle
704 of FIG. 7 bonded together. In this exemplary embodiment the
bond between the adhesive 712 and the upper shingle 702 and the
lower shingle 704 is enhanced relative to that illustrated in FIGS.
2 and 5. As such, the likely failure mode is that of the adhesive
712 itself as illustrated in FIG. 9. That is, the bonds between the
adhesive 712 and the bond enhancing material 706 and between the
adhesive 712 and the reinforcement material 714 can be stronger
than the adhesive material itself. As such, the bond between the
upper shingle 702 and the lower shingle 704 predominantly fails
only when the adhesive material itself fails. In one exemplary
embodiment, a bond strength between an upper shingle 702 and a
lower shingle 704 that are bonded together by an adhesive 712 that
bonds to the bond enhancing material 706 of the upper shingle 702
and a reinforcement material 714 of the lower shingle 704 greater
than bonds formed without the bond enhancing material. For example,
testing has returned bond strengths that are approximately 30%
greater than the bond strength between two shingles that are bonded
together by an adhesive that bonds to the granules of one shingle
and to the particles (often referred to as "backdust") of another
shingle.
[0054] As shown in the known example of FIG. 10, an adhesive 1012
of an upper shingle 1002 can fail to contact the nailing
reinforcement material 1008 of a lower shingle 1004. This may occur
as the result of a thicker than expected particle coating 1006 on
the lower surface of an upper shingle 1002, a thicker than expected
granule coating 1010 on the upper surface of a lower shingle 1004,
a thinner application of adhesive 1012, etc. As was disclosed in
FIGS. 7-9, a bond enhancing material 706 may be used to improve the
bond between an upper shingle 1002 and a lower shingle 1004. A
similar bond enhancing material may be used to overcome the problem
illustrated in FIG. 10.
[0055] FIG. 11 illustrates a bond enhancing material 1106 is
adapted to be thick enough to overcome a gap between an adhesive
1012 and nailing reinforcement material 1008 that may be caused by
particle thickness 1108 or other variables in the structure of an
upper shingle 1102 and a lower shingle 1104. In one exemplary
embodiment, the bond enhancing material 1106 can be thicker than
the nailing reinforcement material 1008. In other words, sized to
protrude past the surface formed by the particles and/or as thick
or thicker than the depth of a depression created by the nailing
reinforcement material 1008 when granules 1110 are not applied in
the area of nailing the reinforcement material 1008.
[0056] FIG. 12 illustrates the upper shingle 1102 and lower shingle
1104 after these two shingles are brought into contact with each
other as would be the case when installed on a roof. As is
illustrated, the bond enhancing material 1106 causes the adhesive
1012 to protrude such that it comes into contact with the nailing
reinforcement material 1008 and thus securely bond the upper
shingle 1102 with the lower shingle 1104.
[0057] FIG. 13 illustrates an exemplary embodiment of a shingle
1300. The illustrated shingle 1300 has an overlay substrate 1302
and an underlay substrate 1304. The exemplary embodiment of the
shingle 1300 also comprises a release material 1306, such as a tape
or a coating. This release material 1306 is intended to prevent an
adhesive 1312 applied to the shingle 1300 from adhering to other
shingles (not illustrated) when packaged in bundles for shipment
and storage. In order to provide a more secure attachment to the
roof, a nailing reinforcement material 1308, which can be a tape,
woven strip, non-woven strip, fibers, or a coating, is applied to
the top side of the overlay substrate 1302. In addition to
reinforcing the nail zone, the reinforcing material can also
enhance adhesion of the adhesive 1312 to the shingle as was
described in the discussion of the previous figures. In exemplary
embodiments, an adhesion enhancing material 1310, which can be a
tape, woven strip, non-woven strip, fibers, such as glass fibers or
a coating is applied to the bottom side of the underlay substrate
1304. In exemplary embodiments in which the adhesion enhancing
material 1310 comprises glass fibers, the glass fibers can be
provided in the form of a glass mat or tape, such as a porous glass
mat or tape.
[0058] The adhesion enhancing material 1310 can be the same width
as the nailing reinforcement material 1308, narrower than the
nailing reinforcement material 1308, or wider than the nailing
reinforcement material 1308. In certain exemplary embodiments, the
adhesive 1312 is disposed on the adhesion enhancing material 1310
and the adhesion enhancing material 1310 is the same width or wider
than the nailing reinforcement material 1308. In certain exemplary
embodiments, the adhesive 1312 is disposed on the nailing
reinforcement material 1308 and the adhesion enhancing material
1310 is the same width or narrower than the nailing reinforcement
material 1308. In certain exemplary embodiments, the nailing
reinforcement material 1308 and/or the adhesion enhancing material
1310 are is between 0.25 inches wide and 2.0 inches wide, such as
about 0.5 inches wide, about 0.75 inches wide, about 1.0 inches
wide, about 1.25 inches wide, or about 1.50 inches wide.
[0059] The adhesive 1312 can be applied to the adhesion enhancing
material 1310 and/or the nailing reinforcement material 1308. Note
that shingles 1300 generally have a layer of granules disposed on
the top surface of the substrates 1302 and 1304 and a layer of
particles or other material disposed on a back side of the shingle.
These granules and particles are not shown in FIGS. 13-27 and 29-31
so as to clearly illustrate the various adhesion promoting
materials applied to the shingle (i.e., 1310) as discussed above
and elsewhere herein.
[0060] In exemplary embodiments, the adhesion enhancing material
1310 may be formed from materials selected from a list comprising:
polyester, polypropylene, polyethylene, polyamide, polystyrene,
polyethylene terephthalate, polyacrylonitrile, and aramid. Any
synthetic polymer or other material or combination of materials
that increases adhesion with the adhesive 1312 and/or the asphalt
coating of the shingle can be used. Any of these materials can be
applied as a mat or tape, a powder, as a suspension in water or
another carrier sprayed on or roll coated onto the shingle.
[0061] In one exemplary embodiment, the adhesion enhancing material
1310 is formed simply by spraying the asphalt coated substrate 1304
with pure water prior to the application of particles to the lower
surface of the substrate 1304. This water would prevent the
particles from sticking to the sprayed (or otherwise applied) area.
As a result, the adhesion enhancing material 1310 comprises the
coating asphalt itself, without granules on the asphalt.
[0062] FIG. 14 illustrates a top-view of the shingle 1300 according
to an exemplary embodiment. As shown, a nailing reinforcement
material 1308 is applied to the overlay substrate 1302. Also
illustrated is the underlay substrate 1304 visible through
decorative openings 1314 formed in the overlay substrate 1302. The
position of the nailing reinforcement material 1308 is such that is
located along that portion of the shingle 1300 to which nails,
staples, or other fasteners are applied in order to affix the
shingle 1300 to a roof structure.
[0063] FIG. 15 illustrates a bottom-view of the shingle 1300 of
FIG. 13. Illustrated in the Figure is the release material 1306,
applied to the overlay substrate 1302. As shown, the underlay
substrate 1304 overlaps a portion of the overlay substrate 1302. an
adhesion enhancing material 1310 is applied along an edge 1316 of
the shingle 1300. Adhesive 1312 is applied to the adhesion
enhancing material 1310. As can be seen, the adhesive 1312 is
applied along the length of the adhesion enhancing material 1310.
The illustrated embodiment shows a series of adhesive 1312
portions. Alternatively, the amount of adhesive 1312 applied could
be a continuous application along all or a portion of the adhesion
enhancing material 1310.
[0064] FIG. 16 illustrates a partial roof portion showing an upper
shingle 1602 and a lower shingle 1604 where the upper shingle 1602
has not been applied to the lower shingle 1604. As shown, the
illustrated shingles are formed from an overlay substrate 1606 and
an underlay substrate 1608, for example, in the manner described
above in FIG. 13. for ease of explanation, it should be understood
that in most cases the upper shingle 1602 and the lower shingle
1604 would be identical and thus, common identifiers are used for
the components of each except where required to reference a
particular shingle. The raised portions 1610 on either side of the
first nailing reinforcement material 1612 and the second nailing
reinforcement material 1612A represent the thickening effect that
the applied granules have on the overlay substrate 1606 of the
shingles.
[0065] In certain exemplary embodiments, the nailing reinforcement
material 1612 and 1612A includes an upper surface to which granules
substantially will not adhere, thus resulting in the area of the
nailing reinforcement material 1612 and 1612A not being coated with
granules as the result of the manufacturing process. Also
illustrated is a first adhesion promoting material 1614 and a
second adhesion promoting material 1614A and a first adhesive 1616
and a second adhesive 1616A.
[0066] FIG. 17 illustrates the upper shingle 1602 and the lower
shingle 1604 of FIG. 16 after the upper shingle 1602 is placed in
contact with the lower shingle 1604. In an actual installation,
nails, staples, or other fasteners would be applied through the
first nailing reinforcement material 1612 to secure the shingles to
the roof surface. However, these are not illustrated in FIG. 17 for
sake of clarity. As illustrated, the first adhesive 1616 of the
upper shingle 1602 is aligned with and comes into contact with the
second nailing reinforcement material 1612A.
[0067] As has been noted elsewhere herein, shingles can take a
plurality of construction forms. One other such construction form
is illustrated in the shingle 1800 of FIG. 18. As shown, a single
substrate 1802 is used in this type of embodiment. The illustrated
shingle 1800 comprises a release material 1806, a nailing
reinforcement material 1808 is applied to the top surface of the
substrate 1802. An adhesion promoting material 1810 is applied to
the bottom surface of the substrate 1802 along an edge 1814 of the
substrate and an adhesive 1812 is applied to the adhesion promoting
material 1810. FIG. 19 is a top view of a shingle 1800 similar or
the same in construction to that of FIG. 18. A nailing
reinforcement material 1808 is applied to the shingle 1800 in an
area in which nails, staples, or other fasteners are applied to
affix the shingle 1800 to a roof.
[0068] FIG. 20 illustrates a bottom-view of a shingle 1800 similar
or the same in construction to that of FIG. 18. Illustrated in the
Figure is a release material 1806, applied to the substrate 1802.
An adhesion promoting material 1810 is applied along an edge 1814
of the shingle 1800. An adhesive 1812 is applied to the adhesion
promoting material 1810. As can be seen, the adhesive 1812 is
applied along the length of the adhesion promoting material 1810.
The illustrated embodiment shows a series of adhesive 1812
portions. Alternatively, the amount of adhesive 1812 applied could
be a continuous application along all or a portion of the adhesion
promoting material 1810.
[0069] FIG. 21 illustrates a partial roof portion showing an upper
shingle 2102 and a lower shingle 2104 similar or the same in
construction to that of FIG. 18. As shown, the upper shingle 2102
has not been applied to the lower shingle 2104. In contrast to FIG.
16, the illustrated shingles are a single-layer shingle (that is,
have only a single layer of substrate). In certain exemplary
embodiments, the nailing reinforcement material 2108 includes an
upper surface to which granules substantially will not adhere, thus
resulting in the area of the nailing reinforcement material 2108
not being coated with granules as the result of the manufacturing
process. Also illustrated is a first adhesion promoting material
2110 and a second adhesion promoting material 2110A and a first
adhesive 2112 and a second adhesive 2112A. Also visible is the
release material 2106 on the lower surface of the upper shingle
2102 and lower shingle 2104.
[0070] FIG. 22 illustrates the upper shingle 2102 and the lower
shingle 2104 of FIG. 21 after the upper shingle 2102 is placed in
contact with the lower shingle 2104. In an actual installation,
nails, staples, or other fasteners would be applied through the
nailing reinforcement material 2108 to secure the shingles to the
roof surface however, these are not illustrated in FIG. 22 for sake
of clarity. As illustrated, the first adhesive 2112 of the upper
shingle 2102 is aligned with and comes into contact with the second
nailing reinforcement material 2108A.
[0071] FIG. 23 illustrates another exemplary embodiment of a
shingle 2300. In the example illustrated by FIG. 23, the adhesive
2312 is applied to the top surface of the shingle 2300. The
adhesive 2312 can be applied to the top surface of the shingle in
any of the embodiments disclosed herein. In the example illustrated
by FIG. 23, the adhesive 2312 is applied to the nailing
reinforcement material 2308. The adhesive 2312 can be applied to
the nailing reinforcement material 2308 and/or the adhesion
promoting material 2310 in any of the embodiments disclosed herein.
Further, the nailing reinforcement material 2308 can be omitted in
any of the embodiments disclosed herein and the adhesive 2312 can
be applied to the top and/or of the bottom of the shingle 2300.
[0072] As shown in FIG. 23, a single substrate 2302 is used in this
type of embodiment. The illustrated shingle 2300 comprises a
release material 2306, a nailing reinforcement material 2308 is
applied to the top surface of the substrate 2302. An adhesion
promoting material 2310 is applied to the bottom surface of the
substrate 2302 along an edge 2314 of the substrate. An adhesive
2312 is applied to the nailing reinforcement material 2308. FIG. 24
shows a top view of the shingle 2300 of FIG. 23. Visible is the
nailing reinforcement material 2308 and the adhesive 2312. FIG. 25
is a bottom view of the shingle 2300 of FIG. 23. Visible is the
release material 2306 and the adhesion promoting material 2310
positioned along the edge 2314 of the substrate 2302.
[0073] FIG. 26 illustrates a partial roof portion showing an upper
shingle 2302 and a lower shingle 2303 similar or the same in
construction to that of FIG. 23. As shown, the upper shingle 2302
has not been applied to the lower shingle 2303. In certain
exemplary embodiments, the nailing reinforcement material 2308
includes an upper surface to which granules substantially will not
adhere, thus resulting in the area of the nailing reinforcement
material 2308 not being coated with granules as the result of the
manufacturing process. Illustrated is a first adhesion promoting
material 2310 and a second adhesion promoting material 2310A. A
first adhesive 2312 and a second adhesive 2312A. Also visible is
the release material 2306 on the lower surface of the upper shingle
2302 and the release material 2306A on the lower shingle 2303.
[0074] FIG. 27 illustrates the upper shingle 2302 and the lower
shingle 2303 of FIG. 26 after the upper shingle 2302 is placed in
contact with the lower shingle 2303. In an actual installation,
nails, staples, or other fasteners would be applied through the
nailing reinforcement material 2308 to secure the shingles to the
roof surface however, these are not illustrated in FIG. 27 for sake
of clarity. As illustrated, the second adhesive 2312A, located on
the lower shingle 2303 is aligned with and comes into contact with
the adhesion promoting material 2310 located on the bottom of the
upper shingle 2303. As with the other exemplary embodiments, thus
contact between the second adhesive 2312A and the first adhesion
promoting material 2310 results in improved resistance to high
winds.
[0075] FIG. 28 illustrates an exemplary apparatus 10 that may be
used to fabricate shingles according to exemplary embodiments
described herein. In the illustrated embodiment, the fabrication
process involves passing a continuous sheet of substrate 12 in a
machine direction (indicated by the arrows) through a series of
manufacturing operations.
[0076] In a first step of the illustrated fabrication process, a
continuous sheet of substrate 12 is removed from a roll 14. The
substrate 12 can be any type known for use in reinforcing
asphalt-based roofing materials, such as a non-woven web of glass
fibers. The substrate 12 may be fed through a coater 16 where an
asphalt coating is applied to the substrate 12. The asphalt coating
can be applied in any suitable manner. In the illustrated
embodiment, the substrate 12 contacts a roller 17, which is in
contact with a supply of hot, melted asphalt. The roller 17
completely covers the substrate 12 with a tacky coating of hot,
melted asphalt to define a first asphalt coated substrate 18. In
other embodiments, however, the asphalt coating could be sprayed
on, rolled on, or applied to the substrate by other means. A
continuous strip of a nailing reinforcement material 19, is removed
from a roll 20. The nailing reinforcement material 19 is adhered to
the first asphalt coated substrate 18 to define a second asphalt
coated substrate 22. In some exemplary embodiments, the nailing
reinforcement material 19 is attached to the first asphalt coated
substrate 18 by the adhesive mixture of the asphalt in the first
asphalt coated substrate 18. The nailing reinforcement material 19,
however, may be attached to the first asphalt coated substrate 18
by any suitable means, such as other adhesives.
[0077] The resulting second asphalt coated substrate 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 substrate 22. The granule dispensers can be of any type
suitable for depositing granules onto the asphalt coated substrate.
An example of a granule dispenser that can be used is a granule
valve of the type disclosed in U.S. Pat. No. 6,610,147 to
Aschenbeck.
[0078] As shown in the exemplary embodiment illustrated in FIG. 28,
the series of dispensers 24 may include four color blend blenders
26, 28, 30, and 32. Any desired number of blenders, however, can 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 substrate 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 substrate
22 by the series of dispensers 24, the second asphalt coated
substrate 22 thus becomes a granule covered substrate 40.
[0079] The granule covered substrate 40 may then be turned around a
slate drum 44 to press the granules into the asphalt coating and to
temporarily invert the substrate so that the excess granules will
fall off and may be recovered and reused. While the granule coated
substrate 40 is inverted, particles (backdust, sand, or other
material) 110 (See FIG. 1) can be applied to the back surface of
the shingle. These particles keeps the shingle from sticking to the
manufacturing equipment illustrated by FIG. 28 and from sticking to
adjacent shingles in a stack during shipment and storage.
[0080] In shingle configurations with an overlay and underlay
substrate (such as is illustrated in FIG. 13), a pattern cutter 52
comprising an upper roller 56 and a lower roller 54 cuts the
granule covered substrate 40 into a continuous underlay substrate
66 and a continuous overlay substrate 68. The underlay substrate 66
may be directed to be aligned beneath the overlay substrate 68, and
the two substrates may be laminated together to form a continuous
laminated assembly of substrates 70. Further downstream, the
continuous laminated substrates 70 may cut by a rotary length
cutter 72 that cuts the laminated substrate into individual
laminated shingles 74.
[0081] 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 84, 86 and 88 can be used to
synchronize the continuous underlay substrate 66 with the
continuous overlay substrate 68. Sensors 90 can also be used to
synchronize any notches and cutouts formed in the continuous
laminated substrates with the end cutter or length cutter 72.
[0082] In some exemplary embodiments, nailing reinforcement
material may be attached to the shingle substrate 12 prior to the
application of the asphalt coating, as shown at 19A in FIG. 28. The
nailing reinforcement material 19A may be attached to the shingle
substrate 12 by any suitable means, such as hot, melted asphalt, or
other adhesives. In other exemplary embodiments, a nailing
reinforcement material may be attached to the granule covered
substrate 40, as shown at 19B in FIG. 28. The nailing reinforcement
material 19B may be attached to the granule covered substrate 40 by
any suitable means, such as hot, melted asphalt, or other
adhesives.
[0083] In some exemplary embodiments, the adhesion promoting
material and release materials are attached to a lower surface
(downwardly facing as viewed in FIG. 7) of the substrate 12, the
first asphalt coated substrate 18, the second asphalt coated
substrate 22, or the granule covered substrate 40, as shown at 19C
and 19D in FIG. 28 (i.e. before or after application of the
granules and before application of the particles 110 on the back
side of the shingle). The adhesion promoting material (i.e., 706 of
FIG. 7) and release materials (i.e., 1306 of FIG. 13) may be
attached to the first asphalt coated substrate 18, the second
asphalt coated substrate 22, or the granule covered substrate 40 by
any suitable means, such as hot, melted asphalt of the asphalt
coated substrate 18, other adhesives, or suitable fasteners. In
other exemplary embodiments, the adhesion promoting material is not
a strip. For example, the adhesion promoting material and/or the
release material can be applied in liquid and/or solid/powder form.
In liquid form, the adhesion promoting material and/or the release
material can be sprayed or rolled onto the substrate. In the
solid/powder form, lanes of the adhesion promoting material and/or
the release material can be dispensed onto the granule coated
substrate 40 when the granule coated substrate is inverted, for
example at drum 44. In one exemplary embodiment, the adhesion
promoting material and/or the release material is provided on the
substrate before particles and the particles does not stick to the
adhesion promoting material and/or the release material. For
example, the adhesion promoting material can be applied at the drum
44, at the position illustrated by reference character 19C, at the
position illustrated by reference character 19D, or at any position
before the substrate 40 is returned to the orientation where the
granules are facing upward.
[0084] As shown in FIG. 29 which represents known methods of
stacking shingles, laminated roofing shingles 2900 are stacked in a
bundle 2902. Only a pair of such shingles 2900 are illustrated in
FIG. 29, with every other shingle 2900 inverted and turned 180
degrees. It will be understood, however, that the shingles 2900 may
be stacked such that every other of such shingles 2900 are either
inverted or turned 180 degrees, or both. This stacking method
minimizes uneven build in the bundle 2902 caused by the difference
in thickness between the area of the shingle 2900 that includes the
underlay substrate 102 and the area that does not include the
underlay substrate 102. A problem may occur, however, along a
central area 2908 of the bundle 2902 because central areas 2910 of
the shingles 2900 are double-layered, whereas the cutout portions
2912 of the shingles 2900 adjacent the central areas 2910 are
single-layered. The difference in thickness causes a ridge or hump
2914 along the central area 2908 of the bundle 2902 that becomes
progressively higher as the number of shingles 2900 in the bundle
2902 increases.
[0085] FIG. 30 is a schematic sectional view of a representative
pair of stacked shingles 3074 manufactured with a nailing
reinforcement material (not visible). As shown in FIG. 25, the
laminated roofing shingles 3074 are stacked such that every other
of the shingles 3074 is inverted and turned 180 degrees relative to
an adjacent one of the shingles 3074 to define a bundle 3099. It
will be understood, however, that the shingles 3074 may be stacked
such that every other of such shingles 3074 are either inverted or
turned 180 degrees, or both. The bundle 3099 includes a central
area 3092. In the illustrated embodiment, the central area 3092
includes the lower zones 3076A and nailing reinforcement material
414 of each shingle 3074 and includes the portion of each laminated
roofing shingle 3074 wherein the shingle 3074 is double-layered. In
contrast to the prior art shingles 2900, when the laminated
shingles 3074 of the invention are stacked, the areas of the
adjacent shingles 3074 having no granules, such as the areas
covered by the nailing reinforcement material 414, cooperate to
advantageously reduce humping in the central area 3092 of the
bundle of stacked shingles 3074. As best shown in FIG. 30, the
central area 3092 of the bundle, as represented by the pair of
shingles 3074 illustrated, has a fourth height 114 substantially
identical to a fifth height 115 of a remainder of the bundle
outside of the central area 3092.
[0086] In addition to the bonding improvements illustrated in FIGS.
8 and 9, a thicker bond enhancing material may be used in the
stacking methods illustrated in FIGS. 29 and 30. The resulting flat
bundles are more easily stacked and less likely to result in stacks
that lean and fall over. Having the bond enhancing material (i.e.,
706 of FIG. 7) which is thicker to enhance bonding also further
reduces the humping in the central area of bundles of stacked
shingles. This is illustrated in FIGS. 31A-31C. FIG. 31A
illustrates a first shingle 3102 and a second shingle 3104 oriented
such that the bottom surface (the side that faces the roof
structure when installed) of the first shingle 3102 is facing the
bottom surface of the second shingle 3104. FIG. 31B shows the first
shingle 3102 and a second shingle 3104 in a position in which the
bond enhancing material 706 is oriented such that is aligned with
the release material (i.e., 1306 of FIG. 13) such that the adhesive
(i.e., 1312 of FIG. 13) is prevented from adhering by the release
material 1306. The result is a shingle stack that has a small gap
at 3112 between the first shingle 3102 and a second shingle 3104.
In practice, the second shingle 3104 flexes slightly to close the
gap. However, the thickness of the bond enhancing material 706
holds the second shingle 3104 predominately flat. In arrangements
without the bond enhancing material 706, the thickness of the
shingles at 3112 could cause a slight "hump." which is less than
the prior art bundle 2902 and also the bundle 3099 illustrated in
FIG. 30. The flat arrangement of FIG. 31B can be stacked into
bundles that do not have any significant hump as illustrated in the
stack 3114 of FIG. 31C. Thus, the arrangement of shingles
illustrated is a significant improvement over shingles without a
bond enhancing material that functions to keep the stacked and
bundled shingles flat. The reduction of bundle humping can also
reduce pressure points of stacked shingles along the common bond
area where the upper edge of the underlay is bonded to the overlay.
This reduction of pressure can reduce or eliminate sticking of
stacked shingles to one another.
[0087] While various inventive aspects, concepts and features of
the disclosures may be described and illustrated herein as embodied
in combination in the exemplary embodiments, these various aspects,
concepts and features may be used in many alternative embodiments,
either individually or in various combinations and sub-combinations
thereof. Unless expressly excluded herein all such combinations and
sub-combinations are intended to be within the scope of the present
application. Still further, while various alternative embodiments
as to the various aspects, concepts and features of the
disclosures--such as alternative materials, structures,
configurations, methods, devices and components, alternatives as to
form, fit and function, and so on--may be described herein, such
descriptions are not intended to be a complete or exhaustive list
of available alternative embodiments, whether presently known or
later developed. Those skilled in the art may readily adopt one or
more of the inventive aspects, concepts or features into additional
embodiments and uses within the scope of the present application
even if such embodiments are not expressly disclosed herein.
Additionally, even though some features, concepts or aspects of the
disclosures may be described herein as being a preferred
arrangement or method, such description is not intended to suggest
that such feature is required or necessary unless expressly so
stated. Still further, exemplary or representative values and
ranges may be included to assist in understanding the present
application, however, such values and ranges are not to be
construed in a limiting sense and are intended to be critical
values or ranges only if so expressly stated. Moreover, while
various aspects, features and concepts may be expressly identified
herein as being inventive or forming part of a disclosure, such
identification is not intended to be exclusive, but rather there
may be inventive aspects, concepts and features that are fully
described herein without being expressly identified as such or as
part of a specific disclosure, the disclosures instead being set
forth in the appended claims. Descriptions of exemplary methods or
processes are not limited to inclusion of all steps as being
required in all cases, nor is the order that the steps are
presented to be construed as required or necessary unless expressly
so stated. The words used in the claims have their full ordinary
meanings and are not limited in any way by the description of the
embodiments in the specification.
* * * * *