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