Note: Descriptions are shown in the official language in which they were submitted.
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HIP AND RIDGE ROOFING MATERIAL
BACKGROUND
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.
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
In accordance with embodiments there are provided shingle blanks. The shingle
blanks include a substrate coated with an asphalt coating and a first fold
region, a second
fold region, a third region, a lower edge and an upper edge. The shingle blank
has a length.
The first fold region extends across the length of the shingle blank. The
second fold region
extends 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. 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. 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.
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According to one embodiment, there is provided a shingle blank comprising: 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, second fold region and the third region each having an
upper surface,
the first fold region extending across the length of the shingle blank, the
second fold region
extending 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; and a reinforcement material positioned
over the first
perforation line and configured to reinforce the first perforation line and to
facilitate
folding of the shingle blank at the first perforation line, the reinforcement
material
including a plurality of apertures configured to allow the asphalt coating to
bleed through
the reinforcement material; wherein the portion of the shingle blank where the
asphalt
coating has bled through the reinforcement material forms a reinforced region
and a
plurality of granules are located on the reinforced region, and wherein the
first and second
perforation lines are configured 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.
According to another embodiment, there is provided a shingle blank comprising:
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, second fold region and the third region each having an
upper surface,
the first fold region extending across the length of the shingle blank, the
second fold region
extending 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; a reinforcement material positioned over
the first
perforation line and configured to reinforce the first perforation line and to
facilitate
folding of the shingle blank at the first perforation line, the reinforcement
material
including a plurality of apertures configured to allow the asphalt
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coating to bleed through the reinforcement material, wherein a plurality of
granules are
located on the portion of the shingle blank where the asphalt coating has bled
through the
reinforcement material; and a release tape 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 configured to reinforce the second perforation line; wherein the first
and second
perforation lines are configured 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.
According to another embodiment, there is provided a method of installing an
asphalt-based roofing material, comprising 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, second fold region and the third
region each having
an upper surface, the first fold region extending across the length of the
shingle blank, the
second fold region extending 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 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 and to facilitate folding
of the shingle
blank at the first perforation line, the reinforcement material including a
plurality of
apertures configured to allow the asphalt coating to bleed through the
reinforcement
material, wherein a plurality of granules are located on the portion of the
shingle blank
where the asphalt coating has bled 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.
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According to another embodiment, there is provided a method of manufacturing
asphalt-based shingle blanks, comprising the steps of: coating a substrate
with an asphalt
coating to form an asphalt coated sheet, the substrate comprising a lower edge
and an
upper ledge, a height defined between the lower edge and upper edge and a
length;
applying a reinforcement material to a portion of an upper surface of the
asphalt coated
sheet, wherein the reinforcement material includes a plurality of apertures,
wherein the
asphalt coating of the substrate bleeds through the plurality of apertures of
the
reinforcement material to form a reinforcement region on a portion of the
upper surface of
the asphalt coated sheet; applying a surface layer of granules to the upper
surface of the
asphalt coated sheet including the reinforcement region; forming a first
perforation line in
the substrate along the length of the substrate, wherein the reinforcement
material is
positioned to cover the first perforation line; forming a second perforation
line in the
substrate along the length of the substrate; wherein a first fold region is
formed between
the second perforation line and the upper edge of the substrate, wherein a
second fold
region is formed between the first perforation line and the second perforation
line, and
wherein a third region is formed between the first perforation line and the
lower edge.
According to another embodiment, there is provided a method of manufacturing
asphalt-based shingle blanks, comprising the steps of: coating a continuous
sheet of
substrate with an asphalt coating to form an asphalt coated sheet, the
substrate comprising
a lower edge and an upper ledge, a height defined between the lower edge and
upper edge
and a length; applying a strip of reinforcement material to a portion of an
upper surface of
the asphalt coated sheet; applying a surface layer of granules to the upper
surface of the
asphalt coated sheet; forming a first perforation line in the substrate along
the length of the
substrate, wherein the reinforcement material is positioned to cover the first
perforation
line; forming a second perforation line in the substrate along the length of
the substrate;
wherein a first fold region is formed between the second perforation line and
the upper
edge of the substrate, wherein a second fold region is formed between the
first perforation
line and the second perforation line, and wherein a third region is formed
between the first
perforation line and the lower edge.
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According to another embodiment, there is provided a method of manufacturing
asphalt-based shingle blanks, comprising the steps of: coating a substrate
with an asphalt
coating to form an asphalt coated sheet, the substrate comprising a lower edge
and an
upper ledge, a height defined between the lower edge and upper edge and a
length;
applying a strip of reinforcement material to a portion of an upper surface of
the asphalt
coated sheet; applying a surface layer of granules to the upper surface of the
asphalt coated
sheet; forming a first perforation line in the substrate along the length of
the substrate,
wherein the reinforcement material is positioned to cover the first
perforation line; forming
a second perforation line in the substrate along the length of the substrate;
wherein a first
fold region is formed between the second perforation line and the upper edge
of the
substrate, wherein a second fold region is formed between the first
perforation line and the
second perforation line, and wherein a third region is formed between the
first perforation
line and the lower edge; applying a release tape to a portion of a lower
surface of the
asphalt coated sheet, wherein the release tape is positioned to cover the
second perforation
line; forming at least two additional perforation line in the substrate that
extends across the
height of the substrate and cutting the substrate into a plurality of discrete
shingle blanks,
wherein each shingle blank comprises a lower edge, an upper edge, a height
defined
between the lower edge and upper edge, a length, a first perforation line and
a second
perforation line that extend across the length of the shingle blank, and two
additional
perforation lines that extend across the height of the shingle blank, a first
fold region
formed between the second perforation line and the upper edge of the shingle
blank, a
second fold region formed between the first perforation line and the second
perforation line
of the shingle blank, and a third region formed between the first perforation
line and the
lower edge of the shingle blank.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a building structure incorporating the hip and
ridge
roofing material in accordance with embodiments of this invention.
Fig. 2 is a perspective view of the installation of the ridge roofing material
of Fig.
1.
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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.
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.
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.
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.
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.
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.
Fig. 9 is a side view in elevation of an individual hip and ridge material of
Fig. 2.
Fig. 10 is a schematic view in elevation of apparatus for manufacturing the
hip and
ridge roofing material of Fig. 2.
Fig. 11 is a perspective view of a second embodiment of a shingle blank used
for
making the hip and ridge roofing material illustrating an upper surface.
Fig. 12 is a perspective view of a bottom surface of the shingle blank of Fig.
11.
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Fig. 13 is an enlarged cross-sectional view, taken along the line 13-13 of
Fig. 11,
of a portion of the shingle blank of Fig. 11.
Fig. 14 is a perspective view of the shingle blank of Fig. 11 illustrating the
formation of the individual hip and ridge roofing material.
Fig. 15 is a side view in elevation of the shingle blank of Fig. 11 prior to
forming
hip and ridge roofing material.
Fig. 16 is a side view in elevation of the shingle blank of Fig. 11
illustrating the
folds forming the hip and ridge roofing material.
Fig. 17 is a side view in elevation of a second embodiment of an individual
hip and
ridge roofing material.
Fig. 18 is a plan view of a reinforcement material used in the shingle blank
of Fig.
11.
DETAILED DESCRIPTION OF THE INVENTION
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.
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.
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
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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.
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
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.
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.
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.
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
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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.
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.
As shown in Fig. 3, an optional reinforcement material 36 is positioned on the
upper surface 27a. The reinforcement material 36 is positioned over the first
perforation
line 34 in the shingle blank 26 and is configured to prevent breakage of the
shingle blank
26 as the shingle blank 26 is folded about the first perforation line 34. In
one
embodiment, the reinforcement material 36 is a tape formed from a polymeric
material. In
other embodiments, the reinforcement material 36 can be made of other suitable
materials.
However, configuring the shingle blank 26 to include a reinforcement material
36 is
optional and not necessary for the use of the shingle blank 26.
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.
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. 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 1.75 inches (4.44 cm), the height HSF is
approximately
2.00 inches (5.08 cm) and the height HT is approximately 8.25 inches (20.95
cm). 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.
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.
The term
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"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.
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 and hip roofing materials 24.
Referring again to Fig. 3, optionally the shingle blank 26 can include a
sealant line
66. The sealant line 66 is configured to provide an adhesive seal for
subsequent
overlapping hip and ridge roofing materials 24. The sealant line 66 can be any
suitable
adhesive and can be applied in any form or configuration in any location. In
one
embodiment, the sealant line 66 can be a continuous strip (not shown) or
continuous strips
(not shown) having a constant width. Alternatively, the sealant line 66 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. Patent No. 4,738,884 to Algrim et
al.
As shown in Fig. 4, the lower surface 27b of the shingle blank 26 includes an
optional release tape 39. 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 66
as the shingle
blanks 26 are stacked for storage or shipping. In the illustrated embodiment,
the release
tape 39 is made of a polymeric material. In other embodiments, the release
tape 39 can be
made of other desired materials or combinations of materials. In still other
embodiments,
the release tape 39 can have any desired coating or combination of coatings.
The release
tape 39 can have any configuration, orientation and dimensions suitable to
cover the
optional sealant line 66 as the shingle blanks 26 are stacked for storage or
shipping.
However, configuring the shingle blank 26 to include a release tape 39 is
optional and not
necessary for the use of the shingle blank 26.
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,
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mixtures of mineral and synthetic fibers, or the like. Combinations of
materials can also
be used in the substrate 44.
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 term "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.
A layer of granules 42 is pressed into the upper surface 52 of the upper
section 48
on either side of the reinforcement material 36. 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.
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 roofing material 24.
In the
illustrated embodiment, each of the formed hip and ridge roofing materials 24
has a length
of approximately 12.0 inches (30.48 cm). 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 roofing materials having lengths of more or less than
approximately 12.0
inches (30.48 cm).
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
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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.
In one example of a perforation pattern, the perforations 64 can be about 0.25
inches (.64 cm) long and spaced apart from edge to edge by about 0.25 inches
(.64 cm). In
another embodiment of a perforation pattern, the perforations 64 can be about
0.50 inches
(1.27 cm) long and spaced apart from edge to edge about 0.50 inches (1.27 cm).
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 hip and ridge shingle blanks 69 at
an installation
site. While the embodiment shown in Fig. 6 illustrates two perforation lines,
60 and 62, it
should be understood that more or less than two perforation lines, sufficient
to enable an
installer to separate the shingle blanks 26 into the hip and ridge shingle
blanks 69, can be
used.
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 hip and ridge shingle blanks 69. The perforations 64 allow the 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.
Referring now to Figs. 7-8, the hip and ridge shingle blanks 69 are formed
into the
hip and ridge roofing materials 24 as shown in Fig. 9 by a series of folds.
First, as shown
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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 Fl 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 66 is shown
on the first
fold region 25a. Folding the hip and ridge single blanks 69 and forming the
three layered
stack 53 forms the hip and ridge roofing materials 24. As shown in Fig. 9, the
resulting
three layered stack 53 can have aligned edges or offset edges.
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 is
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.
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.
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 continuous 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
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(137 meters/minute) and about 800 feet/minute (244 meters/minute). The
continuous
sheet 72, however, may move at any desired speed.
In a first step of the illustrated manufacturing process, the continuous sheet
72 of
substrate or shingle mat is payed out from a roll 74. The continuous sheet 72
can be any
type of substrate known for use in reinforcing asphalt-based roofing
materials, such as a
non-woven web of glass fibers. The continuous sheet 72 may be fed through a
coater 78
where an asphalt coating is applied to the continuous sheet 72. The asphalt
coating can be
applied in any suitable manner. In the illustrated embodiment, the continuous
sheet 72
contacts a roller 73, that is in contact with a supply of hot, melted asphalt.
The roller 73
completely covers the continuous sheet 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 continuous sheet 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.
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.
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. Patent 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 the granules are deposited on the second asphalt coated
sheet 83 by the
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series of granule dispensers 84, the second asphalt covered sheet 83 becomes a
granule
covered sheet 85.
In one embodiment, the reinforcement material 36 includes an upper surface to
which granules substantially will not adhere. The reinforcement material 36,
however,
may include an upper surface or portions of an upper surface to which granules
will
adhere. For example, the apparatus 70 may include any desired means for
depositing
granules onto substantially the entire second asphalt coated sheet 83, except
for the
portion of the second asphalt coated sheet 83 covered by the reinforcement
material 36, as
best shown in Fig. 3. Alternately, granules may be deposited onto
substantially the entire
second asphalt coated sheet 83, including the reinforcement material 36, but
wherein the
reinforcement material 36 includes an upper surface or portions of an upper
surface to
which granules substantially will not adhere.
The granule covered sheet 85 is then turned around a slate drum 86 configured
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.
Turning the third asphalt coated sheet around the slate drum forms inverted
sheet 88.
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.
In the embodiment illustrated in Fig. 10, a backdust applicator 92 is
positioned to
apply a thin layer of backdust material 94 to a bottom surface of the taped
inverted sheet
90. The backdust material 94 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 94 is
sand.
Alternatively, the backdust material 94 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 94 to the taped inverted sheet 90 forms dusted inverted
sheet 96.
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Subsequent to the application of the backdust material 94 to the taped
inverted
sheet 90, the dusted inverted sheet 96 is turned around a sand drum 101 to
press the
backdust material 94 into the bottom surface of the dusted inverted sheet 96.
Pressing the
backdust material 96 into the dusted inverted sheet 96 forms pressed sheet
102.
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.
The cooled sheet 105 is passed through optional sealant applicator 106. The
sealant applicator 106 is configured to apply the sealant line 66 to the first
fold region 25a
of the cooled sheet 105. The sealant applicator 106 can be any suitable
mechanism for
in applying the sealant line 66 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 sealant line 66 to the cooled sheet 105
forms sealant
lined sheet 107.
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. 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.
While Fig. 10 illustrates one example of an apparatus 70 configured for
forming
the perforations 64 and cutting the individual shingle blanks 26, it should be
understood
that other suitable mechanisms or combinations of mechanisms can be used.
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 66 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.
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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.
Referring now to Figs. 11-18, a second embodiment of a shingle blank will be
discussed. Referring first to Figs. 11 and 12, hip and ridge roofing materials
are made
from a shingle blank 226. The shingle blank 226 has an upper surface 227a, a
lower
surface 227b, an upper edge 229a, a lower edge 229b, a generally horizontal
first
perforation line 234 and a generally horizontal second perforation line 240.
As shown in Fig. 11, a reinforcement material 236 is positioned on the upper
surface 227a of the shingle blank 226 and over the first perforation line 234.
The
reinforcement material 236 is configured for several purposes. First, the
reinforcement
material 236 is configured to prevent breakage of the shingle blank 226 as the
shingle
blank 226 is folded about the first perforation line 234. Second, as will be
explained in
more detail below, the reinforcement material 236 is configured to allow
asphaltic
material to bleed through the reinforcement material 236, thereby providing a
surface for
subsequently applied one or more layers of granules to adhere to. In the
illustrated
embodiment, the reinforcement material 236 is a tape made from a polymeric
film
material, such as for example polyester. In other embodiments, the
reinforcement material
236 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 236 extends substantially across the
length L of
the shingle blank 226. 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.
Referring now to Fig. 18, the reinforcement material 236 is illustrated. The
reinforcement material 236 has a width WRM and a thickness. In the illustrated
embodiment, the width WRM of the reinforcement material 236 is in a range of
from
about 1.0 inches (2.54 cm) to about 2.0 inches (5.08 cm) and the thickness is
in a range of
from about 50 gauge (0.0127 mm) to about 96 gauge (0.0244 mm). In other
embodiments,
the width WRM of the reinforcement material 236 can be less than about 1.0
inches (2.54
cm) or more than about 2.0 inches (5.08 cm) and the thickness can be less than
about 50
gauge (0.0127 mm) or more than about 96 gauge (0.0244 mm).
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As shown in Fig. 18, the reinforcement material 236 includes a plurality of
apertures 237. The apertures 237 are configured to allow asphaltic material to
bleed
through the reinforcement material 236. In the illustrated embodiment, the
apertures 237
are arranged in a pattern of columns and rows are present in concentrations of
approximately 330 per square inch (2128 per square cm). Alternatively, the
apertures 237
can be arranged randomly or in other patterns and can have concentrations of
less than 330
per square inch (2128 per square cm) or more than 330 per square inch (2128
per square
cm). In the illustrated embodiment, the apertures 237 have a circular shape
with diameter
in a range of from about 300 microns (0.3 mm) to about 500 microns (0.5 mm).
Alternatively, the apertures 237 can have a diameter less than about 300
microns (0.3 mm)
or more than about 500 microns (0.5 mm). In still other embodiments, the
apertures 237
can have other desired shapes, including the non-limiting examples of square,
and
polygonal shapes as well as slits.
Referring again to Fig. 11, the shingle blank 226 has a length L-2 and a
height H-2.
In the illustrated embodiment, the length L-2 and the H-2 are the same as, or
similar to, the
length L and the height H of the shingle blank 26 discussed above and as shown
in Fig. 3.
However, in other embodiments, the length L-2 and the H-2 can be different
from the
length L and the height H of the shingle blank 26.
As shown in Fig. 11, the shingle blank 226 includes a first fold region 225a,
a
second fold region 225b and a third region 230. The first fold region 225a is
the area
between the second perforation line 240 and the upper edge 229a. The first
fold region
225a is configured to provide a nailing surface for the installation of the
hip and ridge
roofing material 24 and further configured to provide an optional sealant
area. The
optional sealant area will be discussed in more detail below. The second fold
region 225b
is the area between the second perforation line 240 and the first perforation
line 234. The
first fold region 225a has a height HFF-2, the second fold region 225b has a
height HSF-2
and the third region 230 has a height HT-2. In the illustrated embodiment, the
heights
HFF-2, HSF-2 and HT-2 are the same as, or similar to, the heights HFF, HSF and
HT
discussed above and as shown in Fig. 3. However, in other embodiments, the
heights
HFF-2, HSF-2 and HT-2 can be different from the heights HFF, HSF and HT.
Referring again to Fig. 11, the first fold region 225a, second fold region
225b and
third region 230 extend substantially across the length L of the shingle blank
226.
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As further shown in Fig. 11, the shingle blank 226 includes a third and fourth
perforation line, 260 and 262. As will be discussed in more detail below, the
third and
fourth perforation lines, 260 and 262, are configured to allow separation of
the shingle
blank 226 into three pieces, thereby forming ridge or hip roofing materials
24.
Referring again to Fig. 11, optionally the shingle blank 226 can include a
sealant
line 266b. In the illustrated embodiment, the sealant line 266b is the same
as, or similar
to, the sealant line 66 discussed above and shown in Fig. 3. However in other
embodiments, the sealant line 266b can be different from the sealant line 66.
Referring now to Fig. 12, the lower surface 227b of the shingle blank 226
includes
a release tape 239 and an optional sealant line 266a. The release tape 239 is
positioned on
the lower surface 227b of the shingle blank 226 in a location suitable to
cover the optional
sealant line 266b and also to cover the second perforation line 240. The
release tape 239
is configured for several purposes. First, the release tape 239 is configured
to cover the
optional sealant line 266b as shingle blanks 226 are stacked for storage or
shipping.
Second, the release tape 239 is configured to prevent breakage of the shingle
blank 226 as
the shingle blank 226 is folded about the second perforation line 240. In the
illustrated
embodiment, the release tape 239 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
239 can be made of other desired materials or combinations of materials and
can have
thicknesses less than about 30 gauge (0.007 mm) or more than about 96 gauge
(0.024
mm).
Referring again to Fig. 12, the optional sealant line 266a is configured to
provide
an adhesive seal for subsequent overlapping hip and ridge roofing materials
24. In the
illustrated embodiment, the sealant line 266a is the same as, or similar to,
the optional
sealant line 266b illustrated in Fig. 11 and discussed above. Alternatively,
the sealant line
266a can be different from the sealant line 266b. In some embodiments, when
the shingle
blanks 226 are stacked for storage and shipping, the shingle blanks 226 are
flipped such
that the release tape 239 of one shingle blanks substantially aligns with the
sealant line
266a of a subsequently stacked shingle blank. This alignment allows for easy
separation
of the stacked shingle blanks 226 at an installation site.
Referring again to the embodiment illustrated in Fig. 12, the release tape 239
has a
width WRT in a range of from about 3.00 inches (7.62 cm) to about 4.00 inches
(10.16
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cm). However, in other embodiments, the width WRT of the release tape 239 can
be less
than about 3.00 inches (7.62 cm) or more than about 4.00 inches (10.16 cm). In
still other
embodiments, the release tape 239 can have any desired coatings.
Referring now to Fig. 13, one embodiment of the composition of the shingle
blank
226 is illustrated. The shingle blank 226 includes a substrate 244 that is
coated with an
asphalt coating 246. In the illustrated embodiment, the substrate 244 is the
same as, or
similar to, the substrate 44 discussed above and shown in Fig. 5. In other
embodiments,
the substrate 244 can be different from the substrate 44.
The asphalt coating 246 includes an upper section 248 that is positioned above
the
substrate 244 when the roofing material is installed on a roof, and a lower
section 250 that
is positioned below the substrate 244. The upper section 248 includes an upper
surface
252. In the illustrated embodiment, the asphalt coating 246 is the same as, or
similar to,
the asphalt coating 46 discussed above and shown in Fig. 5. In other
embodiments, the
asphalt coating 246 can be different from the asphalt coating 46.
Referring again to Fig. 13, the reinforcement material 236 is positioned on
the
upper surface 252 of the upper section 248 such that portions of the asphalt
coating 246
bleed through the apertures (not shown) within the reinforcement material 236.
The
portion of the asphalt coating 246 that has bled through the reinforcement
material 236
forms a reinforced portion 251 of the upper section 248. The reinforced
portion 251 of the
upper section 248 has a thickness TRP. In the illustrated embodiment, the
thickness TRP
of the reinforced portion 251 is in a range of from about 0.05 inches (1.27
mm) to about
0.30 inches (7.62 mm). In other embodiments, the thickness TRP of the
reinforced portion
251 can be less than about 0.05 inches (1.27 mm) or more than about 0.30
inches (7.62
mm).
A layer of granules 242 is pressed into the upper surface 252 and the
reinforced
portion 251 of the upper section 48 and optionally, the lower section 250 can
be coated
with a suitable backdust material 254. In the illustrated embodiment, the
granules 242 and
the backdust material 254 are the same as, or similar to, the granules 42 and
the backdust
material 54 discussed above and illustrated in Fig. 5. However, in other
embodiments, the
granules 242 and the backdust material 254 can be different from the granules
42 and the
backdust material 54.
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Referring now to Fig. 14, the shingle blank 226 includes the third perforation
line
260 and the fourth perforation line 262. The third and fourth perforation
lines, 260 and
262, include perforations 264. In the illustrated embodiment, the third and
fourth
perforation lines, 260 and 262, and the perforations 264 are the same as, or
similar to, the
third and fourth perforation lines, 60 and 62, and perforations 64 discussed
above and
shown in Fig. 6. Alternatively, the third and fourth perforation lines, 260
and 262, and the
perforations 264 can be different from the third and fourth perforation lines,
60 and 62,
and perforations 64.
Referring again to Fig. 14, the perforations 264 are configured such that an
installer is able to separate the shingle blanks 226 into the hip and ridge
shingle blanks
269 at the installation site. Optionally a plurality of headlap courtesy cuts
268a are
positioned in the first fold region 225a and a plurality of prime courtesy
cuts 268b are
positioned in the third region 230 of the shingle blank 226. In the
illustrated embodiment,
the headlap courtesy cuts 268a are configured to substantially align with a
corresponding
prime courtesy cut 268b, and the aligned headlap and prime courtesy cuts, 268a
and 268b,
are further aligned along the perforation lines, 260 and 262. As shown in the
illustrated
embodiment, the headlap courtesy cuts 268a and the prime courtesy cuts 268b
extend
substantially through the thickness of the shingle blank 226. In other
embodiments, the
courtesy cuts, 268a and 268b, can extend through any suitable layers of the
shingle blank
226. The headlap and prime courtesy cuts, 268a and 268b, have a length. In the
illustrated embodiment, the length of the headlap and prime courtesy cuts,
268a and 268b,
is in a range of from about 1.0 inches (2.54 cm) to about 5.0 inches (12.7
cm). In other
embodiments, the length of the headlap and prime courtesy cuts, 268a and 268b,
can be
less than about 1.0 inches (2.54 cm) or more than about 5.0 inches (12.7 cm).
While the
illustrated embodiment shows the headlap courtesy cuts 268a and the prime
courtesy cuts
268b as being the same length, it should be understood that headlap courtesy
cuts 268a
and the prime courtesy cuts 268b can be different lengths. The courtesy cuts,
268a and
268b, are configured to assist the installer in separating the shingle blanks
226. As will be
explained below in more detail, the courtesy cuts, 268a and 268b, are provided
in the
shingle blank 226 during the manufacture of the shingle blank 226.
Referring again to Fig. 14, the shingle blanks 226 arrive at the installation
site
having third and fourth perforation lines 260 and 262. During installation,
the roofing
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installer separates the shingle blank 226 along the third and fourth
perforation lines, 260
and 262 to form the hip and ridge shingle blanks 269 in a manner as discussed
above and a
shown in Fig. 6.
Referring now to Figs. 15-16, the hip and ridge shingle blanks 269 are formed
into
the hip and ridge roofing materials 224 as shown in Fig. 17 by a series of
folds. First, as
shown in Fig. 15, the hip and ridge shingle blank 69 is positioned such that
the upper
surface 227a is facing upward and the lower surface 27b is facing downward.
Next, as
shown in Fig. 16, the second fold region 225b is folded about the first
perforation line 234
in direction F201 at the same time the first fold region 225a is folded about
the second
perforation line 240 in direction F202. As shown in Fig. 17, the folds result
in a three-
layered stack 253 that includes the first fold region 225a, the second fold
region 225b and
the third region 230. The three-layered stack 253 has a leading edge 255. The
optional
sealant line 266b is shown on the first fold region 225a and the optional
sealant line 266a
is shown on the lower surface 227b. Folding the hip and ridge single blanks
269 and
forming the three layered stack 253 forms the hip and ridge roofing materials
224. The
hip and ridge roofing materials 224 are installed in an overlapping manner
similar to the
installation of the hip and ridge roofing materials 24 as previously described
and as shown
in Fig. 2.
As shown in Fig. 17, the resulting three layered stack 253 has substantially
aligned
edges. Optionally, the resulting three layered stack can have offset edges.
While the hip and ridge roofing material 224 illustrated in Fig. 17 shows a
three
layered stack 253, it should be appreciated that the hip and ridge roofing
material 224 can
be practiced with a stack formed by more than three layers. The hip and ridge
roofing
material 224 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.
In one embodiment, the shingle blanks 226 are generally manufactured in a
manner similar to the manufacture of the shingle blanks 26 described above and
illustrated
in Fig. 10 with a few exceptions.
First, as the reinforcement material 236 adheres to the upper surface 227a of
the
asphalt coated sheet, the reinforcement material 236 is configured to allow
asphaltic
material to bleed through the apertures 237 of the reinforcement material 236,
thereby
forming the reinforced portion 251 of the upper section 248 as illustrated in
Fig. 13.
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Second, in addition to being configured to form the perforation lines 34, 40,
60 and
62 and cutting the sealant lined sheet to form individual shingle blanks, the
cutting roller
108a and anvil roller 108b are further configured to form the courtesy cuts,
268a and
268b.
While Fig. 10 illustrates one example of an apparatus 70 configured for
forming
the perforations 264, the optional courtesy cuts 268a and 268b and cutting the
individual
shingle blanks 226, it should be understood that other suitable mechanisms or
combinations of mechanisms can be used.
The shingle blanks 226 are collected and packaged such that the release tape
239
positioned on the lower surface 227b of the shingle blanks 226 covers the
optional sealant
line 266b located on the upper surface 227a of a subsequent shingle blank 226.
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.
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.
19
