U.S. patent application number 15/893874 was filed with the patent office on 2020-11-12 for hip and ridge roofing material.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Lawrence J. Grubka.
Application Number | 20200354958 15/893874 |
Document ID | / |
Family ID | 1000005178507 |
Filed Date | 2020-11-12 |
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United States Patent
Application |
20200354958 |
Kind Code |
A9 |
Grubka; Lawrence J. |
November 12, 2020 |
HIP AND RIDGE ROOFING MATERIAL
Abstract
Shingle blanks including a first fold region, a second fold
region, a third region, a lower edge and an upper edge are
provided. The shingle blank has a length. The first and second fold
regions extend substantially across the length of the shingle
blank. The second fold region is positioned between the first and
third fold regions. A first perforation line is positioned between
the second and third fold regions. A second perforation line is
positioned between the first and second fold regions. A
reinforcement material is positioned over the first perforation
line and configured to reinforce the first perforation line. The
reinforcement material includes apertures configured to allow an
asphalt coating to bleed through the reinforcement material. The
first and second perforation lines facilitate folding of the first
and second fold regions on top of the third region to form a three
layered stack.
Inventors: |
Grubka; Lawrence J.;
(Westerville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20180163405 A1 |
June 14, 2018 |
|
|
Family ID: |
1000005178507 |
Appl. No.: |
15/893874 |
Filed: |
February 12, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14870400 |
Sep 30, 2015 |
9890534 |
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15893874 |
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12702457 |
Feb 9, 2010 |
9151055 |
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14870400 |
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12392392 |
Feb 25, 2009 |
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12702457 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2419/06 20130101;
B32B 2395/00 20130101; E04D 1/20 20130101; Y10T 156/1056 20150115;
E04D 2001/305 20130101; E04D 2001/005 20130101; B32B 37/24
20130101; E04D 1/30 20130101; B32B 2037/243 20130101 |
International
Class: |
E04D 1/30 20060101
E04D001/30; B32B 37/24 20060101 B32B037/24; E04D 1/20 20060101
E04D001/20 |
Claims
1-20. (canceled)
21. A roofing material comprising: a top asphalt-coated layer; a
bottom asphalt-coated layer comprising a front edge and a rear
edge; and an intermediate asphalt-coated layer comprising a front
edge and a rear edge, wherein the intermediate asphalt-coated layer
is disposed between the top layer and the bottom layer; wherein the
front edge of the intermediate asphalt-coated layer is aligned with
an edge of the top asphalt-coated layer; wherein the rear edge of
the intermediate asphalt-coated layer is aligned with the rear edge
of the bottom asphalt-coated layer.
22. The roofing material of claim 21, wherein a reinforcement
material is on an upper surface of the top asphalt-coated
layer.
23. The roofing material of claim 22, wherein asphalt of the top
asphalt-coated layer bleeds through the reinforcement material.
24. The roofing material of claim 21, wherein the top
asphalt-coated layer comprises a non-woven web coated with
asphalt.
25. The roofing material of claim 24, wherein a reinforcement
material is on an upper surface of the top asphalt-coated
layer.
26. The roofing material of claim 25, wherein the asphalt of the
top asphalt-coated layer bleeds through the reinforcement
material.
27. The roofing material of claim 21, wherein the top
asphalt-coated layer comprises a non-woven web of glass fibers
coated with asphalt.
28. The roofing material of claim 21, wherein granules are embedded
in the top asphalt-coated layer.
29. The roofing material of claim 21, wherein backdust is embedded
in the intermediate asphalt coated layer.
30. The roofing material of claim 21, wherein backdust is embedded
in the bottom asphalt coated layer.
31. The roofing material of claim 21, wherein the front edge of the
intermediate asphalt-coated layer is a continuous edge.
32. The roofing material of claim 21, wherein the rear edge of the
intermediate asphalt-coated layer is a continuous edge.
33. The roofing material of claim 21, wherein the rear edge of the
bottom asphalt-coated layer is a continuous edge.
34. The roofing material of claim 21, wherein the bottom
asphalt-coated layer and the intermediate asphalt-coated layer are
formed from a single substrate, in which the substrate comprises a
perforation line that is disposed between the bottom asphalt-coated
layer and the intermediate asphalt-coated layer such that the
intermediate asphalt-coated layer is folded about perforation line
to create the intermediate asphalt-coated layer and the bottom
asphalt-coated layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of
co-pending U.S. patent application Ser. No. 12/392,392, entitled
HIP AND RIDGE ROOFING MATERIAL, filed Feb. 25, 2009, the disclosure
of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Asphalt-based roofing materials, such as roofing shingles,
roll roofing and commercial roofing, are installed on the roofs of
buildings to provide protection from the elements. The roofing
material may be constructed of a substrate such as a glass fiber
mat or an organic felt, an asphalt coating on the substrate, and a
surface layer of granules embedded in the asphalt coating.
[0003] Roofing materials are applied to roofs having various
surfaces formed by roofing planes. The various surfaces and roofing
planes form intersections, such as for example, hips and ridges. A
ridge is the uppermost horizontal intersection of two sloping roof
planes. Hips are formed by the intersection of two sloping roof
planes running from a ridge to the eaves. It would be desirable to
improve the methods used to manufacture hip and ridge roofing
material to be more efficient.
SUMMARY
[0004] In accordance with embodiments of this invention there are
provided shingle blanks. The shingle blanks include a substrate
coated with an asphalt coating and including a first fold region, a
second fold region, a third region, a lower edge and an upper edge.
The shingle blank has a length and the first fold region extends
substantially across the length of the shingle blank. The second
fold region extends substantially across the length of the shingle
blank and is positioned between the first fold region and the third
region. A first perforation line is positioned between the second
fold region and the third region. A second perforation line is
positioned between the first fold region and the second fold
region. A reinforcement material is positioned over the first
perforation line and is configured to reinforce the first
perforation line. The reinforcement material includes a plurality
of apertures configured to allow the asphalt coating to bleed
through the reinforcement material. The first and second
perforation lines are sufficient to facilitate folding of the first
fold region and the second fold region on top of the third region
to form a three layered stack configured to be applied across a
ridge or hip.
[0005] In accordance with other embodiments, there are also
provided shingle blank having a substrate coated with an asphalt
coating and including a first fold region, a second fold region, a
third region, a lower edge and an upper edge. The shingle blank has
a length and the first fold region extends substantially across the
length of the shingle blank. The second fold region extends
substantially across the length of the shingle blank and is
positioned between the first fold region and the third region. A
first perforation line is positioned between the second fold region
and the third region. A second perforation line is positioned
between the first fold region and the second fold region. A release
tape is positioned over the second perforation line and configured
to span a portion of the first fold region and the second fold
region. The release tape is configured to reinforce the second
perforation line. The first and second perforation lines are
sufficient to facilitate folding of the first fold region and the
second fold region on top of the third region to form a three
layered stack configured to be applied across a ridge or hip.
[0006] In accordance with other embodiments, there are also
provided methods of manufacturing an asphalt-based shingle blank
including the steps of coating a substrate with an asphalt coating
to form an asphalt coated sheet, the asphalt coated sheet including
a first fold region, a second fold region, a third region, a lower
edge and an upper edge, the shingle blank having a length, the
first fold region extending substantially across the length of the
shingle blank, the second fold region extending substantially
across the length of the shingle blank and positioned between the
first fold region and the third region, applying a reinforcement
material to a portion of an upper surface of the asphalt coated
sheet and over the first perforation line, the reinforcement
material including a plurality of apertures configured to allow the
asphalt coating to bleed through the reinforcement material,
applying a surface layer of granules to the upper surface of the
asphalt coated sheet, forming a first perforation line between the
second fold region and the third region and forming a second
perforation line between the first fold region and the second fold
region.
[0007] In accordance with other embodiments, there are also
provided methods of installing an asphalt-based roofing material
including the steps of providing an asphalt-based shingle blank
having a substrate coated with an asphalt coating and including a
first fold region, a second fold region, a third region, a lower
edge and an upper edge, the shingle blank having a length, the
first fold region extending substantially across the length of the
shingle blank, the second fold region extending substantially
across the length of the shingle blank and positioned between the
first fold region and the third region, a first perforation line
positioned between the second fold region and the third region, a
second perforation line positioned between the first fold region
and the second fold region, wherein at least one additional
perforation line extends across the shingle blank in a direction
substantially perpendicular to the lower edge of the shingle blank,
a reinforcement material positioned over the first perforation line
and configured to reinforce the first perforation line, the
reinforcement material including a plurality of apertures
configured to allow the asphalt coating to bleed through the
reinforcement material, separating the shingle blank along the at
least one additional perforation line to form separated shingle
blanks, folding the separated shingle blanks along the first and
second perforation lines to form a three layered stack and
installing the hip and ridge shingles across a hip or ridge.
[0008] Various advantages of this invention will become apparent to
those skilled in the art from the following detailed description of
the invention, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a building structure
incorporating the hip and ridge roofing material in accordance with
embodiments of this invention.
[0010] FIG. 2 is a perspective view of the installation of the
ridge roofing material of FIG. 1.
[0011] FIG. 3 is a perspective view of an upper surface of a
shingle blank used for making the hip and ridge roofing material of
FIG. 2.
[0012] FIG. 4 is a perspective view of a bottom surface of a
shingle blank used for making the hip and ridge roofing material of
FIG. 2.
[0013] FIG. 5 is an enlarged cross-sectional view, taken along the
line 5-5 of FIG. 3, of a portion of the hip and ridge roofing
material of FIG. 3.
[0014] FIG. 6 is a perspective view of the shingle blank of FIG. 3
illustrating the formation of the individual hip and ridge roofing
material of FIG. 2.
[0015] FIG. 7 is a side view in elevation of the individual hip and
ridge roofing material of FIG. 6 prior to forming the hip and ridge
roofing material of FIG. 2.
[0016] FIG. 8 is a side view in elevation of an individual hip and
ridge roofing material of FIG. 6 illustrating the folds forming the
hip and ridge roofing material of FIG. 2.
[0017] FIG. 9 is a side view in elevation of an individual hip and
ridge material of FIG. 2.
[0018] FIG. 10 is a schematic view in elevation of apparatus for
manufacturing the hip and ridge roofing material of FIG. 2.
[0019] FIG. 11 is a plan view of a reinforcement material used in
the hip and ridge roofing material of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0021] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0022] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0023] In accordance with embodiments of the present invention, a
hip and ridge shingle, and methods to manufacture the hip and ridge
shingle, are provided. It will be understood the term "ridge"
refers to the intersection of the uppermost sloping roof planes.
The term "roof plane" is defined to mean a plane defined by a flat
portion of the roof formed by an area of roof deck. The term "hip"
is defined to mean the intersection of sloping roof planes located
below the ridge. It will be understood the term "slope" is defined
to mean the degree of incline of a roof plane. The term "granule"
is defined to mean particles that are applied to a shingle that is
installed on a roof
[0024] The description and figures disclose a hip and ridge roofing
material for a roofing system and methods of manufacturing the hip
and ridge roofing material. Referring now to FIG. 1, a building
structure 10 is shown having a shingle-based roofing system 12.
While the building structure 10 illustrated in FIG. 1 is a
residential home, it should be understood that the building
structure 10 can be any type of structure, such as a garage,
church, arena, industrial or commercial building, having a
shingle-based roofing system 12.
[0025] The building structure 10 has a plurality of roof planes
14a-14d. Each of the roof planes 14a-14d can have a slope. While
the roof planes 14a-14d shown in FIG. 1 have their respective
illustrated slopes, it should be understood that the roof planes
14a-14d can have any suitable slope. The intersection of the roof
planes 14b and 14c form a hip 16. Similarly, the intersection of
the roof planes 14b and 14d form a ridge 18. The building structure
10 is covered by the roofing system 12 having a plurality of
shingles 20.
[0026] Referring now to FIG. 2, the shingles 20 are installed on
the various roof decks in generally horizontal courses 22a-22g in
which the shingles 20 overlap the shingles 20 of a preceding
course. The shingles 20 shown in FIGS. 1 and 2 can be any suitable
shingle.
[0027] Hip and ridge roofing materials are installed to protect
hips and ridges from the elements. As shown in FIG. 2, hip and
ridge roofing materials 24 are installed in an overlapping manner
on the ridge 18 and over the shingles 20. In a similar fashion, hip
roofing materials (not shown) are installed on a hip and over the
shingles. The method of installing the hip and ridge roofing
materials 24 will be discussed in more detail below.
[0028] Referring now to FIGS. 3 and 4, hip and ridge roofing
materials 24 are made from a shingle blank 26. The shingle blank 26
has an upper surface 27a, a lower surface 27b, an upper edge 29a, a
lower edge 29b, a generally horizontal first perforation line 34
and a generally horizontal second perforation line 40.
[0029] As shown in FIG. 3, a reinforcement material 36 is
positioned on the upper surface 27a of the shingle blank 26 and
over the first perforation line 34. The reinforcement material 36
is configured for several purposes. First, the reinforcement
material 36 is configured to prevent breakage of the shingle blank
26 as the shingle blank 26 is folded about the first perforation
line 34. Second, as will be explained in more detail below, the
reinforcement material 36 is configured to allow asphaltic material
to bleed through the reinforcement material 36, thereby providing a
surface for subsequently applied one or more layers of granules to
adhere to. In the illustrated embodiment, the reinforcement
material 36 is a tape made from a polymeric film material, such as
for example polyester. In other embodiments, the reinforcement
material 36 can be made from other desired materials, such as the
non-limiting examples of a low permeability mat or scrim made from
fibrous materials or netting. In the illustrated embodiment, the
reinforcement material 36 extends substantially across the length L
of the shingle blank 26. The term "substantially" as used herein,
is defined to mean any desired distance in a range of from between
approximately one-half of the length L to the full length L.
[0030] Referring now to FIG. 11, the reinforcement material 36 is
illustrated. The reinforcement material 36 has a width WRM and a
thickness. In the illustrated embodiment, the width WRM of the
reinforcement material 36 is in a range of from about 1.0 inches to
about 2.0 inches and the thickness is in a range of from about 50
gauge to about 96 gauge. In other embodiments, the width WRM of the
reinforcement material 36 can be less than about 1.0 inches or more
than about 2.0 inches and the thickness can be less than about 50
gauge or more than about 96 gauge.
[0031] As shown in FIG. 11, the reinforcement material 36 includes
a plurality of apertures 37. The apertures 37 are configured to
allow asphaltic material to bleed through the reinforcement
material 36. In the illustrated embodiment, the apertures 37 are
arranged in a pattern of columns and rows are present in
concentrations of approximately 330 per square inch. Alternatively,
the apertures 37 can be arranged randomly or in other patterns and
can have concentrations of less than 330 per square inch or more
than 330 per square inch. In the illustrated embodiment, the
apertures 37 have a circular shape with diameter in a range of from
about 300 microns to about 500 microns. Alternatively, the
apertures 37 can have a diameter less than about 300 microns or
more than about 500 microns. In still other embodiments, the
apertures 37 can have other desired shapes, including the
non-limiting examples of square, and polygonal shapes as well as
slits.
[0032] Referring again to FIG. 3, the shingle blank 26 may have any
desired dimensions. For example, a typical residential roofing
shingle blank 26 has a length L of approximately 36 inches (91.5
cm) and a height H of approximately 12 inches (30.5 cm) high.
However, it will be understood than other desired dimensions may be
used.
[0033] As shown in FIG. 3, the shingle blank 26 includes a first
fold region 25a, a second fold region 25b and a third region 30.
The first fold region 25a is the area between the second
perforation line 40 and the upper edge 29a. The first fold region
25a is configured to provide a nailing surface for the installation
of the ridge or hip roofing material 24 and further configured to
provide an optional sealant area. The optional sealant bonding area
will be discussed in more detail below. The second fold region 25b
is the area between the second perforation line 40 and the first
perforation line 34. The first fold region 25a has a height HFF,
the second fold region 25b has a height HSF and the third region 30
has a height HT. In the illustrated embodiment, the height HFF is
approximately 2.0 inches, the height HSF is approximately 2.0
inches and the height HT is approximately 8.0 inches. In other
embodiments the heights HFF, HSF and HT can be other desired
dimensions, and it will be understood that the heights HFF, HSF,
and HT are largely a matter of design choice.
[0034] Referring again to FIG. 3, the first fold region 25a, second
fold region 25b and third region 30 extend substantially across the
length L of the shingle blank 26.
[0035] As further shown in FIG. 3, the shingle blank 26 includes a
third and fourth perforation line, 60 and 62. As will be discussed
in more detail below, the third and fourth perforation lines, 60
and 62, are configured to allow separation of the shingle blank 26
into three pieces, thereby forming ridge or hip roofing materials
24.
[0036] Referring again to FIG. 3, optionally the shingle blank 26
can include a sealant line 66b. The sealant line 66b is configured
to provide an adhesive seal for subsequent overlapping ridge
roofing materials 24. The sealant line 66b can be any suitable
adhesive and can be applied in any form or configuration in any
location. In one embodiment, the sealant line 66b can be a
continuous strip, not shown or continuous strips, not shown, having
a constant width. Alternatively, the sealant line 66b can be a
discontinuous strip or strips having varying widths. One example of
a sealant line is the sealant line of the type disclosed in U.S.
Pat. No. 4,738,884 to Algrim et al., the disclosure of which is
incorporated herein in its entirety.
[0037] Referring now to FIG. 4, the lower surface 27b of the
shingle blank 26 includes a release tape 39 and an optional sealant
line 66a. The release tape 39 is positioned on the lower surface
27b of the shingle blank 26 in a location suitable to cover the
optional sealant line 66b and also to cover the second perforation
line 40. The release tape 39 is configured for several purposes.
First, the release tape 39 is configured to cover the optional
sealant line 66b as shingle blanks 26 are stacked for storage or
shipping. Second, the release tape 39 is configured to prevent
breakage of the shingle blank 26 as the shingle blank 26 is folded
about the second perforation line 40. In the illustrated
embodiment, the release tape 39 is made of a polymeric film
material having a thickness in a range of about 30 gauge to about
96 gauge. In other embodiments, the release tape 39 can be made of
other desired materials or combinations of materials and can have
thicknesses less than about 30 gauge or more than about 96
gauge.
[0038] Referring again to FIG. 4, the optional sealant line 66a is
configured to provide an adhesive seal for subsequent overlapping
ridge roofing materials 24. In the illustrated embodiment, the
sealant line 66a is the same as the optional sealant line 66b
illustrated in FIG. 3 and discussed above. Alternatively, the
sealant line 66a can be different from the sealant line 66b. In
some embodiments, when the shingle blanks 26 are stacked for
storage and shipping, the shingle blanks 26 are flipped such that
the release tape 39 of one shingle blanks substantially aligns with
the sealant line 66a of a subsequently stacked shingle blank. This
alignment allows for easy separation of the stacked shingle blanks
26 at an installation site.
[0039] Referring again to the embodiment illustrated in FIG. 4, the
release tape has a width WRT in a range of from about 3.00 inches
to about 4.00 inches. However, in other embodiments, the width WRT
of the release tape can be less than about 3.00 inches or more than
about 4.00 inches. In still other embodiments, the release tape 39
can have any desired coatings.
[0040] Referring now to FIG. 5, one embodiment of the composition
of the shingle blank 26 is illustrated. The shingle blank 26
includes a substrate 44 that is coated with an asphalt coating 46.
The substrate 44 can be any suitable substrate for use in
reinforcing asphalt-based roofing materials, including, but not
limited to a nonwoven web, scrim or felt of fibrous materials such
as glass fibers, mineral fibers, cellulose fibers, rag fibers,
mixtures of mineral and synthetic fibers, or the like. Combinations
of materials can also be used in the substrate 44.
[0041] The asphalt coating 46 includes an upper section 48 that is
positioned above the substrate 44 when the roofing material is
installed on a roof, and a lower section 50 that is positioned
below the substrate 44. The upper section 48 includes an upper
surface 52. The team "asphalt coating" means any type of bituminous
material suitable for use on a roofing material, including, but not
limited to asphalts, tars, pitches, or mixtures thereof. The
asphalt can be either manufactured asphalt produced by refining
petroleum or naturally occurring asphalt. The asphalt coating 46
can include various additives and/or modifiers, such as inorganic
fillers or mineral stabilizers, organic materials such as polymers,
recycled streams, or ground tire rubber.
[0042] The reinforcement material 36 is positioned on the upper
surface 52 of the upper section 48 such that portions of the
asphalt coating 46 bleed through the apertures (not shown) within
the reinforcement material 36. The portion of the asphalt coating
46 that has bled through the reinforcement material 36 forms a
reinforced portion 51 of the upper section 48. The reinforced
portion 51 of the upper section 48 has a thickness TRP. In the
illustrated embodiment, the thickness of the reinforced portion 51
is in a range of from about 0.05 inches to about 0.30 inches. In
other embodiments, the thickness TRP of the reinforced portion 51
can be less than about 0.05 inches or more than about 0.30
inches.
[0043] A layer of granules 42 is pressed into the upper surface 52
and the reinforced portion 51 of the upper section 48. The granules
42 can be any desired granules or combination of granules. Some
examples of granules include prime, headlap granules or waste
granules. Optionally, the lower section 50 can be coated with a
suitable backdust material 54.
[0044] Referring now to FIG. 6, the shingle blank 26 includes the
third perforation line 60 and the fourth perforation line 62. The
third and fourth perforation lines, 60 and 62, include perforations
64. The third and fourth perforation lines, 60 and 62, are spaced
apart substantially perpendicular to the lower edge 29b of the
shingle blank 26 and span the height H of the shingle blank 26. The
third and fourth perforation lines, 60 and 62, are positioned such
that subsequent separation of the shingle blank 26 along the third
and fourth perforation lines, 60 and 62, forms hip and ridge
shingle blanks 69. In the illustrated embodiment, the formed hip
and ridge shingle blanks 69 has a length of approximately 12.0
inches. In other embodiments, the third and fourth perforation
lines, 60 and 62, can be positioned relative to each other, to
result in formed hip and ridge shingle blanks 69 having lengths of
more or less than approximately 12.0 inches. In still other
embodiments, the shingle blank 26 can have more than two
perforation lines (not shown), spaced apart substantially
perpendicular to the lower edge 29b of the shingle blank 26 and
spanning the height H of the shingle blank 26. The additional
perforation lines can be configured to separate the shingle blank
26 thereby forming hip and ridge shingle blanks of any desired
sizes.
[0045] In the illustrated embodiment, the perforations 64 extend
through the upper section 48 of the asphalt coating 46, the
substrate 44 and the lower section 50 of the asphalt coating 46. In
other embodiments, the perforations 64 can extend through any
suitable layers of the shingle blank 26. The perforations 64 can be
arranged in any suitable pattern to form the third and fourth
perforation lines, 60 and 62.
[0046] In one example of a perforation pattern, the perforations 64
can be about 0.25 inches long and spaced apart from edge to edge by
about 0.25 inches. In another embodiment of a perforation pattern,
the perforations 64 can be about 0.50 inches long and spaced apart
from edge to edge about 0.50 inches. Alternatively, the
perforations 64 can be any suitable length and can be spaced apart
edge to edge by any suitable length. The perforations 64 are
configured such that an installer is able to separate the shingle
blanks 26 into the hip and ridge shingle blanks 69 at the
installation site. In the illustrated embodiment, the third and
fourth perforation lines, 60 and 62, extend the full height H of
the shingle blank 26. Alternatively, the third and fourth
perforation lines, 60 and 62, can extend any length sufficient to
enable an installer to separate the shingle blanks 26 into the
ridge shingle blanks 69 at an installation site.
[0047] Referring again to FIG. 6, optionally a plurality of headlap
courtesy cuts 68a are positioned in the first fold region 25a and a
plurality of prime courtesy cuts 68b are positioned in the third
region 30 of the shingle blank 26. In the illustrated embodiment,
the headlap courtesy cuts 68a are configured to substantially align
with a corresponding prime courtesy cut 68b, and the aligned
headlap and prime courtesy cuts, 68a and 68b, are further aligned
along the perforation lines, 60 and 62. As shown in the illustrated
embodiment, the headlap courtesy cuts 68a and the prime courtesy
cuts 68b extend substantially through the thickness of the shingle
blank 26. In other embodiments, the courtesy cuts, 68a and 68b, can
extend through any suitable layers of the shingle blank 26. The
headlap and prime courtesy cuts, 68a and 68b, have a length. In the
illustrated embodiment, the length of the headlap and prime
courtesy cuts, 68a and 68b, is in a range of from about 1.0 inches
to about 5.0 inches. In other embodiments, the length of the
headlap and prime courtesy cuts, 68a and 68b, can be less than
about 1.0 inches or more than about 5.0 inches. While the
illustrated embodiment shows the headlap courtesy cuts 68a and the
prime courtesy cuts 68b as being the same length, it should be
understood that headlap courtesy cuts 68a and the prime courtesy
cuts 68b can be different lengths. The courtesy cuts, 68a and 68b,
are configured to assist the installer in separating the shingle
blanks 26. As will be explained below in more detail, the courtesy
cuts, 68a and 68b, are provided in the shingle blank 26 during the
manufacture of the shingle blank 26.
[0048] Referring again to FIG. 6, the shingle blanks 26 arrive at
the installation site having third and fourth perforation lines 60
and 62. During installation, the roofing installer separates the
shingle blank 26 along the third and fourth perforation lines, 60
and 62 to form the hip and ridge shingle blanks 69. The
perforations 64 allow for hip and ridge shingle blanks 69 to be
formed from the shingle blanks 26 as the perforations 64 allow the
substrate 44 and asphalt regions, 48 and 50, to be readily
separated. The hip and ridge shingle blanks 69 have perforated
edges 122. The configuration of the perforations 64 result in a
perforated edge 122 which in some embodiments is somewhat ragged.
As one example, if the individual perforations 64 have a relatively
long length or if a larger quantity of perforations 64 are used,
then the perforation edges 122 are somewhat smoother. Conversely,
if the individual perforations 64 have a relatively short length or
if a fewer number of perforations 64 are used, then the perforation
edges 122 are somewhat more ragged.
[0049] Referring now to FIGS. 7-9, the hip and ridge shingle blanks
69 are formed into the ridge roofing materials 24 by a series of
folds. First, as shown in FIG. 7, the hip and ridge shingle blank
69 is positioned such that the upper surface 27a is facing upward
and the lower surface 27b is facing downward. Next, as shown in
FIG. 8, the second fold region 25b is folded about the first
perforation line 34 in direction F1 at the same time the first fold
region 25a is folded about the second perforation line 40 in
direction F2. As shown in FIG. 9, the folds result in a
three-layered stack 53 that includes the first fold region 25a, the
second fold region 25b and the third region 30. The three-layered
stack 53 has a leading edge 55. The optional sealant line 66b is
shown on the first fold region 25a and the optional sealant line
66a is shown on the lower surface 27b. Folding the hip and ridge
single blanks 69 and forming the three layered stack 53 forms the
ridge roofing materials 24. As shown in FIG. 9, the resulting three
layered stack 53 has substantially aligned edges. Optionally, the
resulting three layered stack can have offset edges.
[0050] Referring again to FIG. 2, the hip and ridge roofing
materials 24 are installed in an overlapping manner on the ridge 18
and over the shingles 20. As a first installation step, a
three-layered stack 53 is cut from a hip and ridge roofing material
24 and fastened to the farthest downwind point on the ridge 18. As
shown in FIG. 2, the direction of the wind in indicated by the
arrow marked W. The three-layered stack 53 can be fastened by any
desired fastening method, such as for example, roofing nails (not
shown). Next, a hip and ridge roofing material 24 is installed over
the three-layered stack 53 such that a portion of the hip and ridge
roofing material 24 overlaps the three-layered stack 53 and the
leading edge 55 of the three-layered stack 53 is facing the wind
direction W. The hip and ridge roofing material 24 is fastened to
the ridge 18 in any desired manner. Additional hip and ridge
roofing materials 24 are installed in a similar fashion until the
ridge 18 is covered.
[0051] While the hip and ridge roofing material 24 illustrated in
FIGS. 2 and 9 illustrates a three layered stack 53, it should be
appreciated that the hip and ridge roofing material 24 can be
practiced with a stack formed by more than three layers. The hip
and ridge roofing material 24 having a stack of more than three
layers would have a corresponding number of fold regions and would
be formed by folding the various fold regions to form the
stack.
[0052] Referring now to FIG. 10, an apparatus 70 for manufacturing
shingle blanks 26 is illustrated. The manufacturing process
involves passing a continuous sheet 72 in a machine direction
(indicated by the arrow) through a series of manufacturing
operations. The sheet 72 usually moves at a speed of at least about
200 feet/minute (61 meters/minute), and typically at a speed within
the range of between about 450 feet/minute (137 meters/minute) and
about 800 feet/minute (244 meters/minute). The sheet 72, however,
may move at any desired speed.
[0053] In a first step of the illustrated manufacturing process, a
continuous sheet of substrate or shingle mat 72 is payed out from a
roll 74. The substrate can be any type known for use in reinforcing
asphalt-based roofing materials, such as a non-woven web of glass
fibers. The shingle mat 72 may be fed through a coater 78 where an
asphalt coating is applied to the shingle mat 72. The asphalt
coating can be applied in any suitable manner. In the illustrated
embodiment, the shingle mat 72 contacts a roller 73, that is in
contact with a supply of hot, melted asphalt. The roller 73
completely covers the shingle mat 72 with a tacky coating of hot,
melted asphalt to define a first asphalt coated sheet 80. In other
embodiments, however, the asphalt coating could be sprayed on,
rolled on, or applied to the shingle mat 72 by other means. In some
embodiments, the asphalt material is highly filled with a ground
stone filler material, amounting to at least about 60 percent by
weight of the asphalt/filler combination.
[0054] A continuous strip of the reinforcement material 36 is then
payed out from a roll 82. The reinforcement material 36 adheres to
the upper surface 27a of the first asphalt coated sheet 80 to
define a second asphalt coated sheet 83. In one embodiment, the
reinforcement material 36 is attached to the first asphalt coated
sheet 80 by the adhesive mixture of the asphalt in the first
asphalt coated sheet 80. The reinforcement material 36, however,
may be attached to the first asphalt coated sheet 80 by any
suitable means, such as other adhesives.
[0055] As discussed above, the reinforcement material 36 is
configured to allow asphaltic material to bleed through the
apertures 37 of the reinforcement material 36, thereby forming the
reinforced portion 51 of the upper section 48 as illustrated in
FIG. 5.
[0056] The resulting second asphalt coated sheet 83 is then passed
beneath a series of granule dispensers 84 for the application of
granules to the upper surface 27a of the second asphalt coated
sheet 83. While the illustrated embodiment shows two granule
dispensers 84, it should be understood that any number of granule
dispensers 84 can be used. The granule dispensers 84 can be of any
type suitable for depositing granules onto the second asphalt
coated sheet 83. 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. The granule dispensers 84 are configured to provide the
desired blend drops of headlap and prime granules. The granule
dispensers 84 are supplied with granules from sources of granules,
not shown. After all the granules are deposited on the second
asphalt coated sheet 83 by the series of granule dispensers 84, the
second asphalt covered sheet 83 becomes a granule covered sheet
85.
[0057] The granule covered sheet 85 is then turned around a slate
drum 86 to press the granules into the asphalt coating and to
temporarily invert the granule covered sheet 85 so that the excess
granules will fall off and will be recovered and reused. The excess
granules falling from the inverted granule covered sheet can be
collected in any desired collection device (not shown), including
the non-limiting example of a backfall hopper. Turning the granule
covered sheet 85 around the slate drum forms inverted sheet 88.
[0058] A continuous strip of the release tape 39 is then payed out
from a roll 89 and applied to the inverted sheet 88. The release
tape 39 adheres to the lower surface 27b of the inverted sheet 88
to define a taped inverted sheet 90. In one embodiment, the release
tape 39 is attached to the inverted sheet 88 by the adhesive
mixture of the asphalt in the inverted sheet 88. The release tape
39, however, may be attached to the inverted sheet 88 by any
suitable means, such as other adhesives.
[0059] In one embodiment as shown in FIG. 10, a backdust applicator
92 is positioned to apply a thin layer of backdust material 54 to a
bottom surface of the taped inverted sheet 90. The backdust
material 54 is configured to adhere to the bottom surface of the
taped inverted sheet 90 and results in a substantially less tacky
bottom surface for downstream shingle production operations. In one
embodiment, the backdust material 54 is sand. Alternatively, the
backdust material 54 can be any material, such as for example
natural rock dust or small glass particles, sufficient to adhere to
the bottom surface of the taped inverted sheet 90 and result in a
substantially less tacky bottom surface. Application of the
backdust material 54 to the taped inverted sheet 90 forms dusted
inverted sheet 96.
[0060] Subsequent to the application of the backdust material 54 to
the taped inverted sheet 90, the dusted inverted sheet 96 is turned
around a sand drum 101 to press the backdust material 54 into the
bottom surface of the dusted inverted sheet 96. Pressing the
backdust material 56 into the dusted inverted sheet 96 forms
pressed sheet 102.
[0061] Referring again to FIG. 10, the pressed sheet 102 is cooled
by any suitable cooling apparatus 104, or allowed to cool at
ambient temperature to form a cooled sheet 105.
[0062] The cooled sheet 105 is passed through optional sealant
applicator 106. The sealant applicator 106 is configured to apply
the optional sealant line 66b to the first fold region 25a of the
cooled sheet 105 and apply the optional sealant line 66a to the
lower surface 27b of the cooled sheet 105. The sealant applicator
106 can be any suitable mechanism for applying the sealant lines,
66a and 66b, to the cooled sheet 105. In the illustrated
embodiment, a single sealant applicator 106 is shown.
Alternatively, any number of sealant applicators 106 can be used.
Application of the optional sealant lines, 66a and 66b, to the
cooled sheet 105 forms sealant lined sheet 107.
[0063] The sealant lined sheet 107 is passed through cutting roller
108a and anvil roller 108b. In the illustrated embodiment, the
rollers, 108a and 108b, are configured to perform several
manufacturing operations. First, the cutting roller 108a and the
anvil roller 108b are configured to form the perforation lines, 34,
40, 60 and 62, each having the perforations 64. As discussed above,
the perforations 64 can have any desired configuration and the
perforation lines, 34, 40, 60 and 62, can be positioned in any
desired location. The cutting roller 108a includes a plurality of
perforating knives 109 configured to form the perforations 64 as
the cutting roller 108a rotates and contacts the sealant lined
sheet 107. The cutting roller 108a and the anvil roller 108b are
also configured to form the courtesy cuts, 68a and 68b. Last, the
cutting roller 108a and the anvil roller 108b are configured to cut
the sealant lined sheet 107 to form individual shingle blanks
26.
[0064] While FIG. 10 illustrates one example of an apparatus 70
configured for forming the perforations 64, the optional courtesy
cuts 68a and 68b and cutting the individual shingle blanks 26, it
should be understood that other suitable mechanisms or combinations
of mechanisms can be used.
[0065] The shingle blanks 26 are collected and packaged such that
the release tape 39 positioned on the lower surface 27b of the
shingle blanks 26 covers the optional sealant line 66b located on
the upper surface 27a of a subsequent shingle blank 26. While the
embodiment shown in FIG. 10 illustrates the perforating and cutting
processes as a single process, it is within the contemplation of
this invention that the perforating and cutting processes can be
completed at different times and by different apparatus.
[0066] While the apparatus is shown and described in terms of a
continuous process, it should be understood that the manufacturing
method can also be practiced in a batch process using discreet
lengths of materials instead of continuous sheets.
[0067] The principle and mode of operation of this invention have
been described in certain embodiments. However, it should be noted
that this invention may be practiced otherwise than as specifically
illustrated and described without departing from its scope.
* * * * *