Note: Descriptions are shown in the official language in which they were submitted.
CA 02773477 2016-07-15
SHINGLE WITH REINFORCED NAIL ZONE
AND METHOD OF MANUFACTURING
Inventor: James S. Belt and Bert W. Elliott
RELATED APPLICATIONS
[0001]
TECHNICAL FIELD
[0002] This invention relates to a shingle, such as a roofing shingle, and
in
particular, to a roofing shingle having an improved nail zone.
BACKGROUND OF THE INVENTION
[0003] Asphalt-based roofing materials, such as roofing shingles, roll
roofing
and commercial roofing, are installed on the roofs of buildings to provide
protection from the elements, and to give the roof an aesthetically pleasing
look.
Typically, the roofing material is constructed of a substrate such as a glass
fiber
mat or an organic felt, an asphalt coating on the substrate, and a surface
layer of
granules embedded in the asphalt coating.
[0004] A common method for the manufacture of asphalt shingles is the
production of a continuous sheet of asphalt material followed by a shingle
cutting
operation, which cuts the material into individual shingles. In the production
of
asphalt sheet material, either a glass fiber mat or an organic felt mat is
passed
through a coater containing hot liquid asphalt to form a tacky, asphalt coated
sheet. Subsequently, the hot asphalt coated sheet is passed beneath one or
more
granule applicators, which discharge protective and decorative surface
granules
onto portions of the asphalt sheet material.
[0005] In certain types of shingles, it is especially desired that the
shingles
define a sufficiently wide area, often known in the industry as the "nail
zone,'' in
order to make installation of roofs using shingles, such as laminated
shingles,
more efficient and secure. One or more lines or other indicia painted or
otherwise marked longitudinally on the surface of the shingle may define such
a
nail zone. It is especially desired that the shingles define a nail zone that
allows
the installers to have some latitude in the nail placement.
[0006] Additionally, the leading edge of some shingles may experience lift
off
in high wind situations. Therefore, there is also a need for shingles where
the
shingles have a sufficiently high nail pull-through value so that the
installed
shingles have improved performance in high wind situations.
SUMMARY OF THE INVENTION
[0007] One or more of the above objects as well as other objects not
specifically enumerated can be achieved by a roofing shingle. In an
embodiment,
the roofing shingle includes an overlay sheet including a headlap portion and
a
tab portion and an underlay sheet secured to the overlay sheet such that a
region
of the underlay sheet overlaps a region of the headlap portion of the overlay
sheet. The overlay sheet has a non-uniform thickness. A reinforcement material
is secured to the headlap portion of the overlay sheet. The reinforcement
material extends beyond the overlapping regions of the headlap portion and the
underlay sheet. The reinforcement material comprises a material and thickness
that together with the headlap portion provide a nail pull-through value that
is at
least 13.3 percent greater than an otherwise identical shingle having no such
reinforcement material. The reinforcement material is secured to a top surface
of
the headlap portion and extends beyond the overlapping regions of the headlap
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portion and the underlay sheet a maximum distance of about 0.12 inches.
[0008] According to another embodiment, there is also provided a roofing
shingle including an overlay sheet having a headlap portion and a tab portion.
The overlay sheet has an overlay sheet height. An underlay sheet is secured to
a
bottom surface of the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet. The underlay
sheet has a height equal to half of the overlay sheet height +/- V8 inch. The
overlay sheet has a non-uniform thickness. A reinforcement material is secured
to a top surface of the headlap portion of the overlay sheet. The
reinforcement
material extends beyond the overlapping regions of the headlap portion and the
underlay sheet. The reinforcement material comprises a material and thickness
that together with the headlap portion provide a nail pull-through value that
is
greater than an otherwise identical shingle having no such reinforcement
material. The reinforcement material extends beyond the overlapping regions of
the headlap portion and the underlay sheet a maximum distance of about 0.12
inches.
[0009] According to a further embodiment, there is also provided a roofing
shingle including an overlay sheet including a headlap portion and a tab
portion
and an underlay sheet secured to a bottom surface of the overlay sheet such
that a
region of the underlay sheet overlaps a region of the headlap portion of the
overlay sheet. The overlay sheet has a non-uniform thickness. A reinforcement
material is secured to a top surface of the headlap portion. The reinforcement
material comprises a material and thickness that together with the headlap
portion
provide a nail pull-through value that is greater than an otherwise identical
shingle having no such reinforcement material. The reinforcement material has
a height. The overlapping regions of the underlay sheet and the headlap
portion
of the overlay sheet have a height. The ratio of the height of the overlapping
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regions to the height of the reinforcement material is in a range of from
about
70% to about 100%.
[0010] According to another embodiment, there is also provided a roofing
shingle having an overlay sheet including a mat and an asphalt coating applied
to
the mat, and defining a headlap portion and a tab portion; an underlay sheet
including a mat and an asphalt coating applied to the mat, the underlay sheet
being secured to the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet; and a woven
reinforcement material secured directly to the asphalt coating on a rear
surface of
the headlap portion of the overlay sheet without extending into the tab
portion.
The woven reinforcement material extends beyond the overlapping regions of the
headlap portion and the underlay. The woven reinforcement material comprises a
material and thickness together with the headlap portion provide a nail pull-
through value that is greater than an otherwise identical shingle having no
such
reinforcement material. The shingle further includes a plurality of granules
secured to the headlap portion of the overlay sheet and not secured to the
woven
reinforcement material. The woven reinforcement material extends beyond the
overlapping regions of the headlap portion and the underlay sheet a maximum
distance of about 0.12 inches. -
[0010a] According to a further embodiment, there is also provided a roofing
shingle having an overlay sheet including a mat and an asphalt coating applied
to
the mat, and defining a headlap portion and a tab portion; an underlay sheet
including a mat and an asphalt coating applied to the mat, the underlay sheet
being secured to the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet; and a woven
reinforcement material secured directly to the asphalt coating on a rear
surface of
the headlap portion of the overlay sheet without extending into the tab
portion.
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The woven reinforcement material extends beyond the overlapping regions of the
headlap portion and the underlay. The woven reinforcement material comprises a
material and thickness that together with the headlap portion provide a nail
pull-
through value that is within a range of from about 10 percent to about 100
percent greater than an otherwise identical shingle having no such
reinforcement
material. The woven reinforcement material extends beyond the overlapping
regions of the headlap portion and the underlay sheet a maximum distance of
about 0.12 inches.
[0010b] According to another embodiment, there is also provided a roofing
shingle having an overlay sheet including a mat and an asphalt coating applied
to
the mat, and defining a headlap portion and a tab portion; an underlay sheet
including a mat and an asphalt coating applied to the mat, the underlay sheet
being secured to the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet; and a woven
reinforcement material secured directly to the asphalt coating on a rear
surface of
the headlap portion of the overlay sheet without extending into the tab
portion.
The woven reinforcement material extends beyond the overlapping regions of the
headlap portion and the underlay. The woven reinforcement material comprises a
material and thickness that together with the headlap portion provide a nail
pull-
through value that is greater than an otherwise identical shingle having no
such
reinforcement material. The tab portion of the overlay sheet includes a cutout
having an upper edge spaced apart from a lower edge of the woven reinforcement
material by a distance within a range of from about 'A inch to about inch, and
spaced apart from an upper edge of the woven reinforcement material by a
distance within a range of from about 13/4 inches to about 21/4 inches. The
woven
reinforcement material extends beyond the overlapping regions of the headlap
portion and the underlay sheet a maximum distance of about 0.12 inches.
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10010c] According to a further embodiment, there is also provided a roofing
shingle having an overlay sheet including a mat and an asphalt coating applied
to
the mat, and defining an upper headlap portion and a lower tab portion; an
underlay sheet including a mat and an asphalt coating applied to the mat, the
underlay sheet being secured to the overlay sheet such that a region of the
underlay sheet overlaps a region of the headlap portion of the overlay sheet;
and a
reinforcement material secured directly to the asphalt coating of the headlap
portion of the overlay sheet without extending into the tab portion to provide
a
reinforced nail zone along shingle longitudinal axis of the shingle. The
reinforcement material comprises a material and thickness that together with
the
headlap portion provides a nail pull-through value that is greater than an
otherwise identical shingle having no such reinforcement material. The shingle
further includes a granular material secured to the headlap portion of the
overlay
sheet, with no granular material adhered to the reinforcement material. The
reinforcement material has a thinner cross-section than the granular material,
such that the reinforcement material forms a depression in an exterior surface
of
the headlap portion that extends along said longitudinal axis. At least about
70%
of the reinforcement material is disposed on a dual-layer portion of the
shingle.
[0010d] According to another embodiment, there is also provided a roofing
shingle having an overlay sheet including a mat and an asphalt coating applied
to
the mat, and defining a headlap portion and a tab portion; an underlay sheet
including a mat and an asphalt coating applied to the mat, the underlay sheet
being secured to the overlay sheet such that a region of the underlay sheet
overlaps a region of the headlap portion of the overlay sheet; and a
reinforcement
material secured directly to the asphalt coating on the headlap portion of the
overlay sheet without extending into the tab portion to provide a reinforced
nail
zone along a longitudinal axis of the shingle, wherein the reinforcement
material
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comprises a material and thickness that together with the headlap portion
provide
a nail pull-through value that is greater than an otherwise identical shingle
having
no such reinforcement material. The reinforcement material extends beyond the
overlapping regions of the headlap portion and the underlay, such that a first
portion of the reinforcement material is disposed on a dual-layer portion of
the
shingle and a second portion of the reinforcement material is disposed on a
single-layer portion of the shingle. At least about 70% of the reinforcement
material is disposed on a dual-layer portion of the shingle.
[0011] Various objects and advantages of this invention will become
apparent
to those skilled in the art from the following detailed description of the
various
embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Fig. 1 is a schematic elevational view of an apparatus for making
shingles according to the invention.
[0013] Fig. 2 is a perspective view of a laminated shingle having a
reinforcement member in accordance with this invention.
[0014] Fig. 3 is a schematic sectional view of a pair of laminated roofing
shingles of the prior art stacked together, shown in exaggerated thickness to
illustrate humping of the stacked shingles.
[0015] Fig. 4 is a schematic sectional view of a pair of laminated roofing
shingles according to the invention stacked together, shown in exaggerated
thickness to illustrate how the reinforcement members of adjacent shingles
cooperate to reduce humping of the stacked shingles.
[00161 Fig. 5 is a cross-sectional view, in elevation, of a second
embodiment
of a laminated shingle having reinforcement material.
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DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, there is shown in Fig. 1 an apparatus 10 for
manufacturing an asphalt-based roofing material according to the invention. In
the illustrated embodiment, the manufacturing process involves passing a
continuous sheet 12 in a machine direction (indicated by the arrows)
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through a series of manufacturing operations. The sheet usually moves at a
speed
of at least about 200 feet/minute (61 meters/minute), and typically at a speed
within the range of between about 450 feet/minute (137 meters/minute) and
about
800 feet/minute (244 meters/minute). The sheet, however, may move at any
desired speed.
[0018] In a first step of the illustrated manufacturing process, a
continuous
sheet of substrate or shingle mat 12 is payed out from a roll 14. 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 12 may be fed through a
coater 16 where an asphalt coating is applied to the mat 12. The asphalt
coating
can be applied in any suitable manner. In the illustrated embodiment, the mat
12
contacts a roller 17, that is in contact with a supply of hot, melted asphalt.
The
roller 17 completely covers the mat 12 with a tacky coating of hot, melted
asphalt
to define a first asphalt coated sheet 18. In other embodiments, however, the
asphalt coating could be sprayed on, rolled on, or applied to the sheet by
other
means. Typically, 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.
[0019] A continuous strip of a reinforcement material or tape 19, as will
be
described in detail herein, may then be payed out from a roll 20. The
reinforcement tape 19 adheres to the first asphalt coated sheet 18 to define a
second asphalt coated sheet 22. In one embodiment, the reinforcement tape 19
is
attached to the sheet 18 by the adhesive mixture of the asphalt in the first
asphalt
coated sheet 18. The reinforcement tape 19, however, may be attached to the
sheet 18 by any suitable means, such as other adhesives. In one embodiment,
the
tape 19 is formed from polyester. In another embodiment, the tape 19 is formed
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from polyolefin, such as polypropylene or polyethylene. The tape 19, however,
can be formed from any material for reinforcing and strengthening the nail
zone
of a shingle, such as, for example, paper, film, scrim material, and woven or
non-
woven glass.
[0020] The resulting second asphalt coated sheet 22 may then be passed
beneath a series of granule dispensers 24 for the application of granules to
the
upper surface of the second asphalt coated sheet 22. The granule dispensers
can
be of any type suitable for depositing granules onto the asphalt coated sheet.
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 initial granule blender 26 may deposit
partial blend drops of background granules of a first color blend on the tab
portion of the second asphalt coated sheet 22 in a pattern that sets or
establishes
the trailing edge of subsequent blend drops of a second color blend (of an
accent
color) and a third color blend (of a different accent color). For purposes of
this
patent application, the first color blend and the background granules are
synonymous. The use of initially applied partial blend drops to define the
trailing
edge of subsequent blend drops is useful where accurate or sharp leading edges
are possible, but accurate trailing edges at high shingle manufacturing speeds
are
difficult.
[0021] As is well known in the art, blend drops applied to the asphalt
coated
sheet are often made up of granules of several different colors. For example,
one
particular blend drop that is supposed to simulate a weathered wood appearance
might actually consist of some brown granules, some dark gray granules, and
some light gray granules. When these granules are mixed together and applied
to
the sheet in a generally uniformly mixed manner, the overall appearance of
weathered wood is achieved. For this reason, the blend drops are referred to
as
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having a color blend, which gives an overall color appearance. This overall
appearance may be different from any of the actual colors of the granules in
the
color blend. Also, blend drops of darker and lighter shades of the same color,
such as, for example, dark gray and light gray, are referred to as different
color
blends rather than merely different shades of one color.
[0022] As shown in Fig. 1, the series of dispensers 24 includes four color
blend blenders 26, 28, 30, and 32. Any desired number of blenders, however,
can
be used. The final blender may be the background blender 34. Each of the
blenders may be supplied with granules from sources of granules, not shown.
After the blend drops are deposited on the second asphalt coated sheet 22, the
remaining, uncovered areas are still tacky with warm, uncovered asphalt, and
the
background granules from the background blender 34 will adhere to the areas
that
are not already covered with blend drop granules. After all the granules are
deposited on the second asphalt coated sheet 22 by the series of dispensers
24,
the sheet 22 becomes a granule covered sheet 40.
[0023] In one embodiment, the reinforcement tape 19 includes an upper
surface to which granules substantially will not adhere. The reinforcement
tape
19, however, may include an upper surface to which granules will adhere. For
example, the apparatus 10 may include any desired means for depositing
granules
onto substantially the entire second asphalt coated sheet 22, except for the
portion
of the second asphalt coated sheet 22 covered by the tape 19, as best shown in
Fig. 2. Alternately, granules may be deposited onto substantially the entire
second asphalt coated sheet 22, including the tape 19, but wherein the
reinforcement tape 19 includes an upper surface to which granules
substantially
will not adhere.
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[0024] The granule covered sheet 40 may then be turned around a slate drum
44 to press the granules into the asphalt coating and to temporarily invert
the
sheet so that the excess granules will fall off and will be recovered and
reused.
Typically, the granules applied by the background blender 34 are made up by
collecting the backfall granules falling from the slate drum 44.
[0025] The granule covered sheet 40 may subsequently be fed through a rotary
pattern cutter 52, which includes a bladed cutting cylinder 54 and a backup
roll
56, as shown in Fig. 1. If desired, the pattern cutter 52 can cut a series of
cutouts
in the tab portion of the granule covered sheet 40, and cut a series of
notches in
the underlay portion of the granule covered sheet 40.
[0026] The pattern cutter 52 may also cut the granule covered sheet 40 into
a
continuous underlay sheet 66 and a continuous overlay sheet 68. The underlay
sheet 66 may be directed to be aligned beneath the overlay sheet 68, and the
two
sheets may be laminated together to form a continuous laminated sheet 70. As
shown in Fig. 1, the continuous underlay sheet 66 may be routed on a longer
path
than the path of the continuous overlay sheet 68. Further downstream, the
continuous laminated sheet 70 may be passed into contact with a rotary length
cutter 72 that cuts the laminated sheet into individual laminated shingles 74.
[0027] In order to facilitate synchronization of the cutting and laminating
steps, various sensors and controls may be employed. For example, sensors,
such
as photo eyes 86 and 88 can be used to synchronize the continuous underlay
sheet
66 with the continuous overlay sheet 68. Sensors 90 can also be used to
synchronize the notches and cutouts of the continuous laminated sheet with the
end cutter or length cutter 72.
[0028] In one embodiment, the reinforcement tape may be attached to the
shingle mat 12 prior to the application of the asphalt coating, as shown at
19A in
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Fig. 1. The tape 19A may be attached to the shingle mat 12 by any suitable
means, such as hot, melted asphalt, or other adhesives.
[0029] In another embodiment, the reinforcement tape may be attached to the
granule covered sheet 40, as shown at 1913 in Fig. 1. The tape 19B may be
attached to the granule covered sheet 40 by any suitable means, such as hot,
melted asphalt, or other adhesives.
[0030] In another embodiment, the reinforcement tape may be attached to a
lower surface (downwardly facing as viewed in Fig. 1) of the mat 12, the first
asphalt coated sheet 18, the second asphalt coated sheet 22, or the granule
covered sheet 40, as shown at 19C and 19D in Fig. 1. The tape 19C may be
attached to the mat 12, the first asphalt coated sheet 18, the second asphalt
coated
sheet 22, or the granule covered sheet 40 by any suitable means, such as hot,
melted asphalt, other adhesives, or suitable fasteners. In such an embodiment,
the reinforcement tape 19C and 19D may be attached to the lower surface of the
nail zone of either of the overlay sheet 68 or the underlay sheet 66, thereby
reinforcing and strengthening the nail zone as described herein.
[0031] It will be understood, however, that in any of the embodiments
described herein, reinforcement material may be applied as an extruded or
liquid
material, such as a polymer, that will adhere to the mat 12, the first sheet
18, the
second sheet 22, the granule covered sheet 40, or the lower surface of the
underlay sheet 66 or the overlay sheet 68. Additionally, the reinforcement
material may be applied to the laminated roofing shingle 74, as described
below.
[0032] Referring now to Fig. 2, a laminated roofing shingle is shown
generally at 74. In the illustrated embodiment, the shingle 74 includes the
overlay sheet 68 attached to the underlay sheet 66 and has a first end 74A and
a
second end 74B. The shingle 74 also includes a longitudinal axis A. The
overlay
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sheet 68 may include a headlap portion 76 and a tab portion 78. The headlap
portion 76 may include a lower zone 76A and an upper zone 76B. The tab
portion 78 defines a plurality of tabs 80 and cutouts 82 between adjacent tabs
80.
In the illustrated embodiment, the tab portion 78 includes four tabs 80,
although
any suitable number of tabs 80 may be provided. The headlap portion 76 and the
tabs 80 may include one or more granule patterns thereon. Each cutout 82 has a
first height HI. In the illustrated embodiment, the cutouts 82 are shown as
having the same height HI. It will be understood however, that each cutout 82
may be of different heights. A line B is collinear with an upper edge 82A of
the
cutouts 82 and defines an upper limit of an exposed region 84 of the underlay
sheet 66. In the illustrated embodiment, the height of the exposed region 84
is
equal to the first height H1, although the height of the exposed region 84 may
be
any desired height. In a shingle wherein the cutouts 82 have different
heights, the
line B may be collinear with an upper edge 82A of the cutout 82 having the
largest height. In the illustrated embodiment, the overlay sheet 68 has a
second
height H2.
[0033] The reinforcement tape 19 may be disposed longitudinally on the
headlap portion 76. In the illustrated embodiment, the tape 19 extends
longitudinally from the first end 74A to the second end 74B of the shingle 74
within the lower zone 76A of the headlap portion 76. A lower edge 19A of the
tape 19 may be spaced apart from the line B by a distance DI, and an upper
edge
19B of the tape 19 may be spaced apart from the line B by a distance D2. In
one
embodiment, the distance D1 is within the range of from about 'A inch to about
%
inch. In another embodiment, the distance D1 is about 1/2 inch. In one
embodiment, the distance D2 is within the range of from about 1 % inches to
about 2 'A inches. In another embodiment, the distance D2 is about 2 inches.
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The distances D1 and D2 may, however, be of any other desired length. For
example, if desired, the tape 19 may substantially cover the entire headlap
portion
76 of the overlay sheet 68. It will be further understood, however, that one
or
more additional lengths of tape may be disposed longitudinally on the headlap
portion 76, such as shown by the phantom line 19' in Fig. 2. It will be
understood
that the reinforcement material need not extend from the first end 74A to the
second end 74B of the shingle 74, and may be disposed in one or more sections
or portions on the shingle 74.
[00341 The tape 19 defines a nail zone 98 and may include text such as
"nail
here =", as shown in Fig. 2. It will be understood, however, that any other
text or
other indicia may be included on the tape 19. It will also be understood that
the
tape 19 can be provided without such text or indicia. Such indicia on the tape
19
ensure that the nail zone 98 may be easily and quickly identified by the
shingle
installer.
100351 In the embodiment illustrated in Fig. 2, the underlay sheet 66
includes
a leading edge 66A and a trailing edge 66B and has a third height 113. In the
illustrated embodiment, the trailing edge 66B of the underlay sheet 66 is
spaced
apart from the line B by a distance D3. As shown, the distance D3 is about 3/8
inch, however, the distance D3 may be any desired distance.
[0036] In the illustrated embodiment, the third height H3 of the underlay
sheet
66 is less than one-half the second height H2 of the overlay sheet 68. The
overlay sheet 68 and the underlay sheet 66 thereby define a two-layer portion
of
the laminated shingle 74 and a single-layer portion of the laminated shingle
74,
wherein at least a portion of the tape 19 is adhered to the single-layer
portion of
the laminated shingle 74. Alternately, the third height 113 of the underlay
sheet
66 may be equal to one-half the second height H2 of the overlay sheet 68, or
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greater than one-half of the second height H2 of the overlay sheet 68. Such a
relationship between the underlay sheet 66 and the overlay sheet 68 allows the
tape 19 to be positioned such that a reinforced nail zone is provided at a
substantially single-layer portion of the shingle 74.
[0037] In another embodiment of the invention, a layer of material, such as
talc or sand, may be applied to the first asphalt coated sheet 18 shown in
Fig. 1.
The material may be applied by any desired means to an upper surface of the
first
asphalt coated sheet 18. In one embodiment, the material may be applied to the
portion of the first asphalt coated sheet 18 that will become the portion of
the
overlay sheet 66 shown covered by the tape 19 in Fig. 2. Such a material may
reduce tackiness of the portions of the second asphalt coated sheet 22 to
which
the material has been applied, and thereby provide a surface to which granules
substantially will not adhere.
[0038] In the exemplary shingle 74 illustrated in Fig. 2, the shingle 74
may
have a nail pull-through value, measured in accordance with a desired
standard,
such as prescribed by ASTM test standard D3462. For example, the shingle 74
may have a nail pull-through value that is greater than in an otherwise
identical
shingle having no such tape 19. In one embodiment, the shingle 74 may have a
nail pull-through value within the range of from about ten percent to about
100
percent greater than in an otherwise identical shingle having no such tape 19.
In
another embodiment, the shingle 74 may have a nail pull-through value about 50
percent greater than in an otherwise identical shingle having no such tape 19.
[0039] In another embodiment, a shingle having a reinforcement tape 19
formed from polyester film having a thickness of about 0.5 mils, may have a
nail
pull-through value about 13.3 percent greater than in an otherwise identical
shingle having no such tape 19.
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[0040] In another embodiment, a shingle having a reinforcement tape 19
formed from polyester film having a thickness of about 3.0 mils, may have a
nail
pull-through value about 62.3 percent greater than in an otherwise identical
shingle having no such tape 19.
[0041] In another embodiment, a shingle having a reinforcement tape 19
formed from polyester film having a thickness of about 4.0 mils, may have a
nail
pull-through value about 86.0 percent greater than in an otherwise identical
shingle having no such tape 19.
[0042] In another embodiment, a shingle having a reinforcement tape 19
formed from polyester film having a thickness of about 5.0 mils, may have a
nail
pull-through value about 112.7 percent greater than in an otherwise identical
shingle having no such tape 19.
[0043] Because there may be substantially no granules in the portion of the
overlay sheet 68 covered by the tape 19, the weight of the shingle 74 may be
reduced relative to an otherwise identical shingle having no such tape 19. For
example, the weight of the exemplary shingle 74 illustrated in Fig. 2, may be
reduced within the range of from about four percent to about six percent
relative
to the weight of an otherwise identical shingle having no such tape 19. The
material and transportation cost may also be reduced.
[0044] Although the invention has been disclosed in the context of a
laminated shingle 74, it will be understood that the reinforcement tape 19 may
be
attached to any other type of shingle, such as a single layer shingle.
[0045] As shown in Fig. 3, laminated roofing shingles 100 of the prior art
are
stacked in a bundle 102. Only a pair of such shingles 100 are illustrated in
Fig. 3,
with every other shingle 100 inverted and turned 180 degrees. It will be
understood, however, that the shingles 100 may be stacked such that every
other
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of such shingles 100 arc either inverted or turned 180 degrees, or both. This
stacking method minimizes uneven build in the bundle 102 caused by the
difference in thickness between the area of the shingle 100 that includes the
underlay sheet 106 and the area that does not include the underlay sheet 106.
A
problem may occur, however, along a central area 108 of the bundle 102 because
central areas 110 of the shingles 100 are double-layered, whereas the cutout
portions 112 of the shingles 100 adjacent the central areas 110 are single-
layered.
The difference in thickness causes a ridge or hump 114 along the central area
108
of the bundle 102 that becomes progressively higher as the number of shingles
100 in the bundle 102 increases.
100461 Fig. 4 is a schematic sectional view of a representative pair of
stacked
shingles 74 manufactured according to the present invention. As shown in Fig.
4,
the laminated roofing shingles 74 are stacked such that every other of the
shingles 74 is inverted and turned 180 degrees relative to an adjacent one of
the
shingles 74 to define a bundle 99. It will be understood, however, that the
shingles 74 may be stacked such that every other of such shingles 74 are
either
inverted or turned 180 degrees, or both. The bundle 99 includes a central area
92.
In the illustrated embodiment, the central area 92 includes the lower zones
76A
and reinforcement tape 19 of each shingle 74, and includes the portion of each
laminated roofing shingle 74 wherein the shingle 74 is double-layered. In
contrast to the prior art shingles 100, when the laminated shingles 74 of the
invention are stacked, the areas of the adjacent shingles 74 having no
granules,
such as the areas covered by the reinforcement tapes 19, cooperate to
advantageously reduce humping in the central area 92 of the bundle of stacked
shingles 74. As best shown in Fig. 4, the central area 92 of the bundle, as
represented by the pair of shingles 74 illustrated, has a fourth height H4
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substantially identical to a fifth height H5 of a remainder of the bundle
outside of
the central area 92.
[0047] Referring now to Fig. 5, a second embodiment of a laminated roofing
shingle is shown generally at 174. In the illustrated embodiment, the shingle
174
includes an overlay sheet 168 attached to an underlay sheet 166. In the
illustrated
embodiment, the overlay sheet 168 and the underlay sheet 166 are the same as,
or
similar to, the overlay sheet 68 and the underlay sheet 66 described above and
illustrated in Fig. 2. In other embodiments, the overlay sheet 168 and the
underlay sheet 166 can be different from the overlay sheet 68 and the underlay
sheet 66. The shingle 174 has a first end (not shown) and a second end (not
shown). In the illustrated embodiment, the first and second ends of the
shingle
174 are the same as, or similar to, the first end 74A and the second end 74B
described above and illustrated in Fig. 2. In other embodiments, the first and
second ends of the shingle 174 can be different from the first end 74A and the
second end 74B. The shingle 174 also includes a longitudinal axis extending
from the first end to the second end. In the illustrated embodiment, the
longitudinal axis is the same as, or similar to, the longitudinal axis A
described
above and illustrated in Fig. 2. In other embodiments, the longitudinal axis
of the
shingle 174 can be different from the longitudinal axis A.
[0048] Referring again to Fig. 5, the overlay sheet 168 may include a
headlap
portion 176 and a tab portion 178. The headlap portion 176 may include a lower
zone 176A and an upper zone 176B. The tab portion 178 defines a plurality of
tabs 180 and cutouts (not shown) between adjacent tabs 180. Any suitable
number of tabs 180 and cutouts may be provided. The headlap portion 176 may
include any type of granule applied thereon, including headlap granules. The
tabs 180 may include one or more granule patterns applied thereon. In the
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illustrated embodiment, the shingle 174 can be formed in the same manner, or
in
a similar, manner to the manufacturing process described above and illustrated
in
Fig. 1. In other embodiments, the shingle 174 can be formed with other desired
processes.
100491 Referring again to Fig. 5, each cutout has a first height H101. It
should
be understood that the cutouts may be of the same first height H101 or
different
cutouts can have different first heights H101. The cutouts have an upper edge
1 82A that defines an upper limit of an exposed region (not shown) of the
underlay sheet 166. In the illustrated embodiment, the height of the exposed
region is equal to the first height H101, although the height of the exposed
region
may be any desired height. In a shingle wherein the cutouts have different
heights, the upper edge 182A occurs with the cutout having the largest first
height H101. In the illustrated embodiment, the overlay sheet 168 has a second
height H102.
100501 A reinforcement material 119 may be disposed longitudinally on the
headlap portion 176. The reinforcement material 119 is configured to increase
the pull-through of the nail zone in the same manner as the tape 19 described
above and illustrated in Fig. 2. In the illustrated embodiment, the
reinforcement
material 119 is formed from woven fabric made from a polymeric material, such
as the non-limiting example of polyethylene terephthalate (PET). In other
embodiments, the reinforcement material 119 can be formed from other woven
polymeric materials, such as for example, polyester, polyolefin or
polypropylene.
In still other embodiments, the reinforcement material 119 can be formed from
any material configured to reinforce and strengthen the nail zone of a
shingle,
including the non-limiting example of paper, film, scrim material, and woven
or
non-woven glass.
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[0051] In the illustrated embodiment, the reinforcement material 119
extends
longitudinally from the first end to the second end of the shingle 174 within
the
lower zone 176A of the headlap portion 176. A lower edge 119A of the
reinforcement material 119 may be spaccd apart from the upper edge 182A of the
cutouts by a first distance D101, and an upper edge 119B of the reinforcement
material 119 may be spaced apart from the upper edge 182A of the cutouts by a
second distance 1)102. In one embodiment, the first distance 1)101 is within
the
range of from about 0.06 inches to about 0.75 inches. In another embodiment,
the first distance D101 is about 0.25 inches. In one embodiment, the second
distance D102 is within the range of from about 1.06 inches to about 1.75
inches.
In another embodiment, the second distance D102 is about 1.50 inches. The
first
and second distances, D101 and D102, may however, be of any other desired
length. For example, if desired, the reinforcement material 119 may
substantially
cover the entire headlap portion 176 of the overlay sheet 168. It should be
understood, however, that one or more additional lengths of reinforcement
material may be disposed longitudinally on the headlap portion 176, such as
shown in Fig. 2 by the phantom line 19'. In addition, the reinforcement
material
119 need not extend from the first end to the second end of the shingle 174,
and
may be disposed in one or more sections or portions on the shingle 174.
[0052] The reinforcement material 119 defines a nail zone 198 and may
include text or other indicia such as described above for the tape 19 as shown
in
Fig. 2.
[0053] In the embodiment illustrated in Fig. 5, the underlay sheet 166
includes
a lower edge 166A and an upper edge 166B. The distance from the lower edge
166A to the upper edge 166B defines a third height H103. The upper edge 166B
of the underlay sheet 166 is spaced apart from the upper edge 182A by a third
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distance D103. In the illustrated embodiment, the third distance D103 is
within
the range of from about 1.06 inches to about 1.75 inches. In another
embodiment, the third distance D103 is about 1.38 inches. However, the third
distance D103 may be any desired distance.
[0054] Referring again to Fig. 5, the upper edge 166B of the underlay sheet
166 is spaced apart from the upper edge 119B of the reinforcement material 119
by a fourth distance D104. In the illustrated embodiment, the fourth distance
D104 is within the range of from about 0.06 inches to about 0.50 inches. In
another embodiment, the fourth distance D104 is about 0.12 inches. In still
other
embodiments, the fourth distance D104 can be zero. However, the fourth
distance D104 may be any desired distance.
[0055] In the illustrated embodiment, the third height H103 of the underlay
sheet 166 is approximately one-half of the second height H102 of the overlay
sheet 168. The overlay sheet 168 and the underlay sheet 166 thereby define a
two-layer portion of the laminated shingle 174 and a single-layer portion of
the
laminated shingle 174. Such a dimensional relationship between the underlay
sheet 166 and the overlay sheet 168 allows the reinforcement material 119 to
be
positioned such that the nail zone 198 can extend near or over the single-
layer
portion of the shingle 74. The two-layer portion of the laminated shingle 174
that
is covered by the reinforcement material 119 has a fourth height H104. In the
illustrated embodiment, the fourth height H104 is in a range of from about
1.00
inches to about 1.75 inches. In other embodiments, the fourth height H104 can
be other dimensions less than about 1.00 inches or more than about 1.75
inches.
[0056] Referring again to Fig. 5, the reinforcement material 119 has a
fifth
height H105. In the illustrated embodiment, the fifth height H105 is within
the
range of from about 1.06 inches to about 1.87 inches. In another embodiment,
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the fifth height H105 is about 1.38 inches. However, the fifth height H105 may
be any desired distance.
[0057] As discussed above, the relationship of the fourth height H104 and
the
fifth height H105 defines in part the extent to which the reinforcement
material
119 extends beyond the two-layer portion of the shingle 174 and into the
single
layer portion of the shingle. In this regard, the term "coverage", as used
herein, is
defined to mean the percentage of the reinforcement material 119 that covers
the
two-layer portion of the shingle 174. In other words, coverage is the ratio of
the
fourth height H104 to the fifth height H105. As one example, a fourth height
H104 of 1.12 inches and a fifth height H105 of 1.25 inches provides a ratio of
90%, meaning the 90% of the reinforcement material 119 is positioned to cover
the two-layer portion of the shingle 174. In the illustrated embodiment, the
coverage of the reinforcement material 119 is in a range of from about 70% to
about 100%. In other embodiments, the coverage can be in a range of from about
80% to about 95%. In still other embodiments, the coverage can be in a range
of
from about 85% to about 90%.
[0058] In the embodiment illustrated in Fig. 5, the shingle 174 may have a
nail
pull-through value that is the same as, or similar to, the nail pull-through
value
for the shingle 74 as described above and as shown in Fig. 2. Alternatively,
the
shingle 174 can have a nail pull-through value that is different from the nail
pull-
through value for the shingle 74.
[0059] In another embodiment, a shingle 174 having a reinforcement material
119 formed from woven polymeric materials having a thickness of about 0.5
mils, may have a nail pull-through value at least about 13 percent greater
than in
an otherwise identical shingle having no such reinforcement material 119.
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[0060] In another embodiment, a shingle having a reinforcement material 119
formed from woven polymeric materials having a thickness of about 3.0 mils,
may have a nail pull-through value about 62 percent greater than in an
otherwise
identical shingle having no such reinforcement material 119.
100611 In another embodiment, a shingle having a reinforcement material 119
formed from woven polymeric materials having a thickness of about 4.0 mils,
may have a nail pull-through value about 86 percent greater than in an
otherwise
identical shingle having no such reinforcement material 119.
[0062] In another embodiment, a shingle having a reinforcement material 119
formed from woven polymeric materials having a thickness of about 5.0 mils,
may have a nail pull-through value about 112 percent greater than in an
otherwise
identical shingle having no such reinforcement material 119.
[0063] Because there may be substantially no granules in the portion of the
overlay sheet 168 covered by the reinforcement material 119, the weight of the
shingle 174 may be reduced relative to an otherwise identical shingle having
no
such reinforcement material 119. For example, the weight of the exemplary
shingle 174 illustrated in Fig. 5, may be reduced within the range of from
about
four percent to about six percent relative to the weight of an otherwise
identical
shingle having no such reinforcement material 119. The material and
transportation cost may also be reduced.
[0064] Although the invention has been disclosed in the context of a
laminated shingle 174, it will be understood that the reinforcement material
119
may be attached to any other type of shingle, such as a single layer shingle.
[0065] The principle and mode of operation of this invention have been
described in its various embodiments. However, it should be noted that this
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invention may be practiced otherwise than as specifically illustrated and
described without departing from its scope.
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