Note: Descriptions are shown in the official language in which they were submitted.
. ,
ROOFING SHINGLE SYSTEM AND SHINGLES FOR USE THEREIN
100011
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Attorney Docket No. 03398.000057.2 PATENT
APPLICATION
FIELD OF THE INVENTION
[0002] This invention relates to an improved roofing shingle having the
bulk (i.e., thicker
appearance) and configuration of more expensive roofing shingles and a roofing
system that
utilizes the shingles. In particular, the invention relates to roofing
shingles featuring unique
dimensions that improve weather resistance and minimize the amount of material
required to
make the shingles, as well as a roofing system that utilizes the shingles.
BACKGROUND OF THE INVENTION
[0003] Roofing products are often divided into three broad groups:
shingles, roll roofing,
and underlayment. Shingles and roll roofing typically function as outer roof
coverings designed
to withstand exposure to weather and the elements. Shingles and roll roofing
generally contain
the same basic components which provide protection and long term wear
associated with asphalt
roofing products. These components include a base material made from an
organic felt or
fiberglass mat which serves as a matrix to support the other components and
gives the product
the required strength to withstand manufacturing, handling, installation and
service in the
intended environment. An asphalt coating formulated for the particular service
application is
often applied to the base material to provide the desired long-term ability to
resist weathering
and to provide stability under temperature extremes. An outer layer of mineral
granules is also
commonly applied to the asphalt coating to form a surface exposed to the
weather which shields
the asphalt coating from the sun's rays, adds color to the final product and
provides fire
resistance.
[0004] Asphalt shingles are among the most commonly used roofing materials.
Such
shingles are typically manufactured as single layer strip shingles, laminated
shingles having two
or more layers, interlocking shingles and large individual shingles in a
variety of weights and
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colors. Such laminated asphalt shingles are also often referred to as
composite shingles or as
architectural shingles or dimensional shingles. Even though asphalt shingles
offer significant
cost, service life and flammability advantages over slate or wood shingles,
slate or wood shingles
are still often preferred due to the pleasing aesthetic appearance of a slate
or wood shingled roof.
An important aesthetic advantage of such slate or wood shingles is their
greater thickness as
compared to composite shingles. The thickness of slate or wood shingles
results in a more
pleasing, layered look for the finished roof.
[0005] Various composite shingles have been developed to provide an
appearance of
thickness comparable to slate or wood shingles. Examples of such composite
shingles are shown
in U.S. Pat. No. 7,805,905 entitled Roofing Shingle; U.S. Pat. No. 8,397,460
entitled Roofing
Shingle; U.S. Pat. Appl. Publ. No. 2013/0019554 entitled Roofing Shingle; U.S.
Pat. Appl. Publ.
No. 2010/0205898 entitled Roofing Shingle; U.S. Pat. No. D554,275 entitled
Roof Shingle; U.S.
Pat. No. D388,195 entitled Shingle; U.S. Pat. No. D366,124 entitled Tab
Portion Of A Shingle;
U.S. Pat. No. D375,563 entitled Shingle; U.S. Pat. No. D376,660 entitled
Shingle; U.S. Pat. No.
D336,347 entitled Tab Portion Of A Shingle; U.S. Pat. No. D340,294 entitled
Design For A Tab
Portion Of A Shingle; U.S. Pat. No. D366,335 entitled Design For A Tab Portion
Of A Shingle;
U.S. Pat. No. 6,105,329 entitled Trilaminate Roofing Shingle; U.S. Pat. No.
6,220,329 entitled
Apparatus for Making Laminated Roofing Shingles; U.S. Pat. No. 5,102,487
entitled
Manufacturing Roofing Shingles; and assignee's co-pending U.S. Pat. Appl. No.
14/266,294
entitled Roofing Shingle System and Shingles For Use Therein.
[0006] U.S. Pat. Nos. 7,805,905 and 8,397,460, and U.S. Pat. Appl. Publ.
Nos.
2013/0019554 and 2010/0205898 disclose two-layer composite roofing shingles
with a posterior
layer having a posterior headlap and a plurality of posterior tabs extending
from the posterior
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headlap; and an anterior layer, positioned on the posterior layer, having an
anterior headlap and
at least one alignment notch and at least one anterior tab extending from the
anterior headlap,
where at least one anterior tab is positioned on the plurality of posterior
tabs. At least one
anterior tab is absent in two-layer embodiments of the inventions described in
the above
disclosures, such that the shingles have at least one single-layer tab (i.e.,
a posterior tab without a
corresponding anterior tab positioned over said posterior tab). When
installed, this presence and
absence of an anterior tab on the shingles along with the posterior tabs and
optional shadow
bands and shadow tips simulate a variable thickness slate surface.
[0007] U.S. Pat. No. D554,275 illustrates two-layer composite roofing
shingles with a
posterior layer having a posterior headlap and a plurality of posterior tabs
extending from the
posterior headlap and an anterior layer, positioned on the posterior layer,
having an anterior
headlap and at least one anterior tab extending from the anterior headlap,
where each anterior tab
is positioned on a corresponding posterior tab and at least one anterior tab
is absent, such that the
shingles have at least one single-layer tab (i.e., a posterior tab without a
corresponding anterior
tab positioned over it). Each of the anterior tabs has the same shape and
equal breadth that is less
than the breadth of the posterior tabs, each of which has the same shape and
equal breadth, and
the anterior tabs are positioned over the center of a corresponding posterior
tab.
[0008] U.S. Pat. No. D388,195 illustrates a two-layer shingle with an
undivided posterior
layer (i.e., without tabs) and an anterior layer having an anterior headlap
and a plurality of tabs
having crimped corners. The undivided posterior layer has a bottom edge
contour that generally
shadows the bottom edge contour of the anterior tabs. Each of the anterior
tabs has the same
shape and equal breadth and is separated from adjacent anterior tabs by
openings of equal
breadth.
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[0009] U.S. Pat. No. D366,124 illustrates a two-layer tab portion of a
shingle with an
undivided posterior layer (i.e., without tabs) and an anterior layer having an
anterior headlap and
a plurality of tabs having crimped corners. The undivided posterior layer has
a bottom edge
contour that generally shadows the bottom edge contour of the anterior tabs.
Each of the anterior
tabs has the same shape and equal breadth and is separated from adjacent
anterior tabs by
openings of equal breadth.
[00010] U.S. Pat. Nos. D375,563 and D376,660 illustrate three-layer
shingles with an
undivided posterior layer (i.e., without tabs), a middle layer having a
headlap and a plurality of
tabs having crimped corners, and an anterior layer comprising two planks
positioned over the
center of two corresponding middle layer tabs and extending over the middle
layer headlap.
Each of the shingles illustrated has two middle layer tabs without an anterior
layer plank
positioned over the middle layer tab.
[00011] U.S. Pat. Nos. D336,347 and D340,294 illustrate three-layer tab
portions of
shingles with an undivided posterior layer (i.e., without tabs), a middle
layer having a headlap of
indeterminate width and a plurality of tabs having crimped comers, and an
anterior layer
comprising two planks positioned over the center of two corresponding middle
layer tabs and
extending over the fractional middle layer headlap. Each of the shingles
illustrated has two
middle layer tabs without an anterior layer plank positioned over said middle
layer tab.
[00012] U.S. Pat. No. D366,335 illustrates a two-layer tab portion of a
shingle with a
posterior layer comprising a single posterior tab with crimped corners and an
anterior layer
comprising a single anterior tab with crimped corners positioned over the
center of the posterior
tab.
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1000131 U.S. Pat. No. 6,105,329 discloses three-layer roofing shingles with
an anterior
layer having a headlap portion and a butt portion comprising a plurality of
tabs of a given
breadth separated by spaces approximately 0.50 to 1.25 the breadth of an
anterior tab; a middle
layer with the same number of tabs as the anterior tabs; and an undivided
posterior layer (i.e.,
without tabs). The middle layer tabs have a breadth such that the middle layer
tabs partially fill
the spaces between the anterior tabs when the anterior layer is positioned
over the middle layer.
The middle layer tabs have a configuration complementary to, and are the same
height as, the
anterior tabs, such that a middle layer tab mirrors an adjacent anterior tab
when the anterior layer
is positioned over the middle layer. Each tab (e.g., anterior layer tab or
middle layer tab) is a
single layer of roofing material positioned over the undivided posterior
layer, except for
embodiments having an alignment means in the form a small tab in the anterior
layer spaces, in
which case, the middle layer tabs are partially covered by the small anterior
tab and the middle
layer tabs remain positioned over the undivided posterior layer.
[00014] U.S. Pat. No. 6,220,329 discloses three-layer roofing shingles with
an anterior
layer and a mid-layer, each having a headlap portion and a butt portion
comprising a plurality of
tabs of a given breadth separated by spaces, wherein the tabs of the butt
portions of the anterior
layer and mid-layer are offset from each; and an undivided posterior layer
(i.e., without tabs).
1000151 U.S. Pat. No. 5,102,487 discloses a method of making laminated
shingles having
a generally rectangular underlay and an overlay with tabs and cutouts, wherein
roofing material
is cut with a cutting cylinder that has a common factor with the length of the
shingle, other than
the length of the shingle itself, to create a sufficient number of shingles
having a different pattern
of tabs and cutouts to ensure a fairly random appearance when the shingles are
applied onto the
roof.
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[00016] Single layer asphalt shingles have also been developed to provide
an appearance
of thickness comparable to slate or wood shingles, such as U.S. Pat. No.
D313,278 entitled
Shingle.
[00017] U.S. Pat. No. D313,278 illustrates single-layer shingles with a
headlap and four
tabs having crimped corners. Adjacent tabs have different lengths and
alternating tabs have the
same length. Each tab is partially covered with granules of contrasting color
values or shading
with discrete rectangular outlines.
1000181 Various composite shingles have also been developed with slits or
slots as part of
an interlocking shingle roofing system. Examples of such composite or asphalt
shingles are
shown in U.S. Pat. No. 2,801,599 entitled Multiple Tab Square Butt Shingle;
and U.S. Pat. No.
3,973,369 entitled Roofing Shingle.
[00019] U.S. Pat. No. 2,801,599 describes a single-layer tabbed strip
roofing shingle with
substantially horizontal slots that engage interlocking tabs of subsequently
installed courses of
shingles. The horizontal slots are not visible when the shingles are
installed.
[00020] U.S. Pat. No. 3,973,369 describes a two-layered tabbed roofing
shingle with
diagonal slots cut into a body sheet of the shingle, but not a backing sheet
affixed underneath the
body sheet, wherein the slots engage with tab corners of subsequently
installed courses of
shingles. The diagonal slots are not visible when the shingles are installed.
[00021]
SUMMARY OF THE INVENTION
[000221 One embodiment of this invention pertains to a new laminated
asphalt containing
roofing shingle having superior weather resistance and an aesthetic appearance
that simulates a
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variable thickness slate, tile or wood shake roofing surface, and which
further employs a novel
tab configuration and a novel backer to reduce the risk of wind failure.
1000231 A
preferred embodiment of the present invention is a two-layer laminated
shingle,
wherein the shingle has a posterior layer (also known as a backer, e.g., a
backer sheet or backer
strip) and an anterior layer (also known as a facer), wherein the anterior
layer of each shingle has
a plurality of tabs spaced apart by a plurality of openings and the posterior
layer has a plurality of
"partial slots" (defined herein as openings cut into the posterior layer that
do not extend to any
edge of the buttlap, see, e.g., FIG. 1, feature 271), wherein the partial
slots separate the posterior
"simulated tabs" (defined herein as regions of the buttlap of a shingle or
shingle layer that
resemble traditional shingle or shingle layer tabs, but are not completely
separated from adjacent
similar regions at any edge of the buttlap, see, e.g., FIG. 1, feature 13),
wherein the simulated
tabs are connected to at least one adjacent simulated tab by a "connecting
segment" (defined
herein as a portion of shingle or shingle layer material disposed between
simulated tabs, see, e.g.,
FIG. 1, feature 273), wherein the connecting segment may be located at or near
the buttlap edge
of the shingle or shingle layer, and wherein each of the simulated tabs on the
posterior layer
(posterior simulated tabs) are at least partially covered by a tab on the
anterior layer (anterior
tabs) such that the shingle simulates the appearance of a variable thickness
slate, tile or wood
shake roofing surface and better resists wind failure compared to prior art
asphalt shingles that
have been developed to simulate such an appearance. Prior art two-layer
laminated shingles
have simulated the appearance of a variable thickness slate, tile or wood
shake roofing surface by
having at least one posterior tab that is not covered by an anterior tab. See,
e.g., U.S. Pat. No.
7,805,905. A further preferred embodiment of the present invention achieves
the appearance of
shingles having at least one posterior simulated tab that is not covered by an
anterior tab while at
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least partially covering each posterior simulated tab with an anterior tab.
Moreover, the
connecting segments provide additional rigidity to the simulated tabs, while
the partial slots
provide the visual appearance of discrete tabs that help convey the appearance
of bulk.
[00024] In accordance with one embodiment of the present invention, a
roofing system is
provided having a multiplicity of courses of roofing shingles of the
invention, wherein each
shingle has at least a posterior layer and an anterior layer, wherein the
anterior layer of each
shingle has a plurality of tabs spaced apart by a plurality of openings and
the posterior layer of
each shingle has a plurality of simulated tabs spaced apart by a plurality of
partial slots, wherein
the simulated tabs on the posterior layer (posterior simulated tabs) each have
the same breadth
and the tabs on the anterior layer (anterior tabs) each have a breadth that is
(a) narrower than the
breadth of the posterior simulated tabs and (b) selected from at least two
different breadths,
wherein at least two of the anterior tabs have different breadths, and wherein
the openings on the
anterior layer (anterior openings) each have a breadth selected from at least
two different
breadths, wherein at least two of the anterior openings have different
breadths. When installed,
the differing breadths of the anterior tabs and anterior openings create a
visual pattern that may
appear relatively random and aesthetically pleasing. The relatively random
pattern of the
anterior tabs and anterior openings creates the illusion of thickness that
makes the roofing
shingles appear like more expensive roofing materials such as tile, slate, or
wood shakes.
[00025] The illusion of thickness may be further enhanced, for example, by
employing
granules of contrasting hues on the tabs or employing shade lines, including
to the edges or
contours of the tabs according to methods known in the art.
[00026] In a preferred embodiment, the anterior tabs do not cover the
partial slots on the
posterior layer (posterior partial slots).
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[00027] Tabbed two-layer prior art asphalt shingles have utilized
configurations wherein
at least one posterior tab is not covered by an anterior tab to simulate the
random appearance and
increased thicknesses of more expensive roofing materials, such as slate or
wood. See, e.g., U.S.
Pat. No. 7,805,905. Such shingles have tabs that are only one layer thick or
single-layer tabs
(i.e., the posterior tabs that are not covered by an anterior tab). Although
such prior art shingles
have a desirable appearance, the two-layer roofing shingles disclosed in U.S.
Pat. Nos. 7,805,905
are susceptible to wind failure when the shingles are installed in cold
weather. In cold weather
conditions, a relatively modest wind may lift a single-thickness tab, which is
more flexible and
lighter than a more rigid and heavier double thickness tab, prior to it being
fully sealed. When
this occurs, dust and other contaminants may land underneath the affected tab,
causing it to never
fully seal. This affected tab is then susceptible to lifting up due to wind,
which may cause a
chain reaction lifting up adjacent tabs and eventually the entire shingle.
[00028] Applicants herein disclose and claim laminated shingles with a
novel anterior tab
pattern that surprisingly conveys the desirable appearance of laminated
shingles having at least
one single-layer tab (see, e.g., FIG. 7, feature 8), but do not have any prior
art single-layer tabs
susceptible to wind failure. In addition, the inventive shingles result in a
more efficient use of
materials because less scrap pieces are generated during the manufacturing
process compared to
the manufacturing of prior art shingles. Moreover, the connecting segments
provide additional
rigidity to the simulated tabs; thereby providing further resistance to wind
failure.
[00029] In a preferred embodiment, the novel dimensions and configuration
of the anterior
tabs and anterior openings operate to simulate the appearance of uncovered
posterior tabs (e.g.,
U.S. Pat. Nos. 7,805,905), while each posterior simulated tab is at least
partially covered by an
anterior tab (and connected to at least one adjacent simulated tab). The
shingles of the invention
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are believed to deter posterior layer lift up under mild wind conditions prior
to the shingles fully
sealing, and provide improved wind failure resistance after fully sealing
compared to prior art
shingles with single-layer tabs.
1000301 In a preferred embodiment, the shingles of the invention achieve
the desirable
appearance of a multi-layered laminated shingle having single-layer posterior
tabs (i.e.,
uncovered posterior tabs) by employing an anterior layer tab pattern (and
simulated tabs). As a
result of the anterior layer tab pattern, little or no scraps are generated
during formation of the
anterior layer from a sheet of roofing material.
1000311 In a preferred embodiment, a shingle of the invention is a
laminated roofing
shingle comprising:
(a) a posterior layer having a posterior headlap portion and a posterior
buttlap portion including a
plurality of posterior simulated tabs extending from said posterior headlap
portion, said
posterior simulated tabs spaced apart by a plurality of posterior partial
slots, and each of said
posterior simulated tabs is connected to at least one adjacent posterior
simulated tab by a
connecting segment;
(b) an anterior layer having an anterior headlap portion and an anterior
buttlap portion including a
plurality of anterior tabs extending from said anterior headlap portion, said
anterior tabs
spaced apart to define a plurality of anterior openings between said anterior
tabs; and
wherein the anterior layer is positioned on the posterior layer in a manner
such that each anterior tab is positioned
over a posterior simulated tab, wherein the number of posterior simulated tabs
is equal to the number of anterior
tabs, wherein the posterior simulated tabs have a given breadth that is about
equal for each posterior simulated tab,
wherein at least one anterior tab has a first anterior tab breadth and at
least another anterior tab has a second anterior
tab breadth that differs from the first anterior tab breadth, wherein at least
one anterior opening has a first anterior
opening breadth that is about equal to the second anterior tab breadth, and
wherein at least another anterior opening
has a second anterior opening breadth that is about equal to the first
anterior tab breadth.
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[00032] In a further embodiment, it is contemplated that one or more
posterior simulated
tabs may have differing breadths. In order to maintain the same total
coverage, adjacent
posterior simulated tabs should have reciprocal changes in breadth. For
example, if a posterior
simulated tab has a breadth that is 1" wider than the average breadth of the
posterior simulated
tabs, then an adjacent posterior simulated tab should have a breadth that is
1" less than the
average breadth of the posterior simulated tabs.
[00033] In yet a further embodiment, it is contemplated that the anterior
tabs may each
have a different breadth.
[00034] In a preferred embodiment, at least one anterior tab has a first
anterior tab breadth
that is less than 50% the breadth of each posterior simulated tab, and at
least another anterior tab
has a second anterior tab breadth that is 50% or more, but less than 100%, the
breadth of each
posterior simulated tab, and each anterior tab does not extend over any said
posterior partial slot.
[00035] In another preferred embodiment, the shingle has no alignment notch
in the
anterior headlap as opposed to shingles disclosed in U.S. Pat. No. 7,805,905
that have alignment
notches.
[00036] In a further embodiment, it is contemplated that the shingle has
one or more
alignment notches in the anterior headlap. In such embodiment, the posterior
simulated tabs
should each have the same breadth.
[00037] In a preferred embodiment, the shingle has four posterior simulated
tabs and four
anterior tabs.
[00038] In a preferred embodiment, the first anterior tab breadth is about
50% the breadth
of the second anterior tab breadth.
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[00039] In a preferred embodiment, each anterior tab may have right angle
comers and
each anterior opening may have right angle comers. In another preferred
embodiment, the
anterior tabs may have crimped comers and the anterior openings may have
crimped comers. In
yet another preferred embodiment, each anterior tab may have non-straight,
irregular edge
contours. In yet another preferred embodiment, each anterior tab may have an
edge contour that
is stair-stepped, trapezoidal, angular, curved, or jagged.
[00040] In a preferred embodiment, each posterior simulated tab may have
right angle
corners (see, e.g., FIGS. 9 and 10, shingles 90 and 100, respectively) and
each posterior partial
slot may have right angle comers. In another preferred embodiment, each
posterior simulated
tab may have crimped corners (see, e.g., FIG. 1, shingle 10). It is further
contemplated that any
of the aforementioned modifications to the posterior simulated tabs and
posterior partial slots
may be applied to the shingles of the invention in any combination with any of
the
aforementioned modifications to the anterior tabs and anterior openings.
[00041] In a preferred embodiment, the first anterior tab breadth is about
2.88 inches and
the second anterior tab breadth is about 5.75 inches, and the breadth of the
posterior simulated
tabs is about 8.25 inches.
[00042] In a preferred embodiment, the shingle is a two-layer laminated
roofing shingle.
[00043] In a preferred embodiment, a roofing system of the invention
comprises at least
four adjacent shingles, each of the first, second, third, and fourth adjacent
shingles comprising:
(a) a posterior layer having a posterior headlap portion and a posterior
buttlap portion including
four posterior simulated tabs extending from said posterior headlap portion,
said posterior
simulated tabs spaced apart by a plurality of posterior partial slots, and
each of said posterior
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simulated tabs is connected to at least one adjacent posterior simulated tab
by a connecting
segment;
(b) an anterior layer having an anterior headlap potion and an anterior
buttlap portion including
four anterior tabs extending from said anterior headlap portion, said anterior
tabs spaced apart
to define a plurality of anterior openings between said anterior tabs;
wherein the anterior layer is positioned on the posterior layer in a manner
such that each anterior tab is positioned
over a posterior simulated tab, wherein the posterior simulated tabs have a
given breadth that is about equal for each
posterior simulated tab, wherein at least one anterior tab has a first
anterior tab breadth that is less than 50% the
breadth of each posterior simulated tab, wherein at least another anterior tab
has a second anterior tab breadth that is
50% or more, but less than 100% the breadth of each posterior simulated tab;
wherein each of the first, second, and
third adjacent shingles differ from each other based on the positions of the
at least one anterior tab having the first
anterior tab breadth and the at least another anterior tab having the second
anterior tab breadth, and wherein the first
adjacent shingle and the fourth adjacent shingle are identical based on the
positions of the at least one anterior tab
having the first anterior tab breadth and the at least another anterior tab
having the second anterior tab breadth, so
that when installed, a pattern of varying anterior tab breadths is created
based on the respective positions of the
anterior tabs having the first anterior tab breadth and the anterior tabs
having the second anterior tab breadth.
[00044] In a preferred embodiment, shingles of the invention have two
anterior tabs
having said first anterior tab breadth and two anterior tabs having said
second anterior tab
breadth.
[00045] In a preferred embodiment, shingles of the invention have one
anterior tab having
said first anterior tab breadth and three anterior tabs having said second
anterior tab breadth.
[00046] In a preferred embodiment, shingles of the invention have three
anterior tabs
having said first anterior tab breadth and one anterior tab having said second
anterior tab breadth.
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[00047] In a preferred embodiment, a roofing system comprises a plurality
of courses of
shingles of the invention, wherein the shingles are installed on a roof deck
in overlapping
courses.
[00048] In a preferred embodiment, a shingle of the invention is a
laminated roofing
shingle comprising:
(a) a posterior layer having a posterior headlap portion and a posterior
buttlap portion including a
plurality of posterior simulated tabs extending from said posterior headlap
portion, said
posterior simulated tabs spaced apart by a plurality of posterior partial
slots, and each of said
posterior simulated tabs is connected to at least one adjacent posterior
simulated tab by a
connecting segment;
(b) an anterior layer having an anterior headlap portion and an anterior
buttlap portion including a
plurality of anterior tabs extending from said anterior headlap portion, said
anterior tabs
spaced apart to define a plurality of anterior openings between said anterior
tabs; and
wherein the anterior layer is positioned on the posterior layer in a manner
such that each anterior
tab is positioned over a posterior simulated tab, wherein each anterior tab
extends over no
posterior partial slot, wherein the number of posterior simulated tabs is
equal to the number of
anterior tabs, wherein the roofing shingle has a length, wherein the posterior
layer is formed
from a cutting cylinder having a circumference that is equal to the length of
said roofing shingle,
and wherein the anterior layer is formed from a cutting cylinder having a
circumference that is a
fraction of the length of the roofing shingle.
[00049] In a preferred embodiment, the cutting cylinder used to form the
anterior layer
has a circumference that is a 1.5 times the length of said roofing shingle.
[00050] The shingles of the invention are improvements of roofing shingle
materials
known in the art, wherein the improvements are providing roofing shingles
having posterior
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simulated tabs that are each partially covered by an anterior tab that when
installed on a roof
deck operate to simulate the appearance of more expensive roofing material
such as wood, slate,
or tile, and having improved weather performance over the prior art,
especially with respect to
resisting wind failure. A further improvement is a reduction of waste material
during
manufacturing of the shingles of the invention compared to manufacturing of
prior art shingles.
Another improvement is a provision of connecting segments between posterior
simulated tabs
that provides additional rigidity to the posterior simulated tabs, which
further improves
resistance to wind failure.
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DETAILED DESCRIPTION OF THE FIGURES
[00051] For a more complete understanding of the present invention, and
the
advantages thereof, reference is now made to the following descriptions taken
in conjunction
with the accompanying figures, but which are not to be construed as limiting
to the scope of the
present invention as defined by the appended claims, in which:
[00052] FIG. 1 shows a top plan view of an exemplary embodiment of a two-
layer
rooting shingle of the present invention;
[00053] FIG. lA shows a top plan view of the anterior layer of the
shingle of FIG 1.
[00054] FIG. 1B shows a top plan view of the posterior layer of the
shingle of FIG. 1.
[00055] FIG. 2 shows a front elevation view of the exemplary embodiment
of the
roofing shingle of the present invention depicted in FIG. 1;
[00056] FIG. 3 shows a rear elevation view of an exemplary embodiment of
the
roofing shingle of the present invention;
[00057] FIGS. 4, 4A, 4B, and 4C show right side views of various
embodiments of the
roofing shingle of the present invention;
[00058] FIG. 5 shows a perspective view of the exemplary embodiment of
the roofing
shingle of the present invention depicted in FIG. 1;
[00059] FIG. 6 shows a top plan view of another exemplary embodiment of a
two-
layer roofing shingle of the present invention, wherein the anterior tabs and
anterior openings
have crimped corners.
[00060] FIG. 7 shows a top plan view of an exemplary embodiment of a
roofing
system of the present invention incorporating the various two-layer roofing
shingle embodiments
of the present invention;
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[00061] FIG. 8 shows a top plan view of another exemplary embodiment of a
two-
layer roofing shingle of the present invention, wherein the anterior tabs have
stair-stepped edges;
[00062] FIG. 9 shows a top plan view of another exemplary embodiment of a
two-
layer roofing shingle of the present invention, wherein the posterior
simulated tabs have right
angle corners.
[00063] FIG. 10 shows a top plan view of another exemplary embodiment of
a two-
layer roofing shingle of the present invention, wherein the posterior
simulated tabs have right
angle corners and the anterior tabs and anterior openings have crimped
corners.
[00064] FIG. 11 shows a top plan view of another exemplary embodiment of
a two-
layer roofing shingle of the present invention, wherein the anterior tabs and
anterior openings
have non-straight, irregular edge contours.
[00065] FIG. 12 shows a top plan schematic of a sheet of roofing material
from which
is cut two separate tabbed anterior layers of a prior art two-layer roofing
shingle.
[00066] FIG. 13 shows a top plan schematic of a sheet of roofing material
from which
is cut two separate tabbed anterior layers corresponding to the anterior
layers of the shingles of
FIG. 1. Also accompanying the sheet of roofing material are two pre-cut
posterior layers
corresponding to the posterior layers of the shingles of FIG. 1.
[00067] FIGS. 14-18 show top plan views of additional exemplary
embodiments of the
roofing shingle of the present invention, wherein two anterior tabs have a
first breadth and two
anterior tabs have a second breadth.
[00068] FIGS. 19-22 show top plan views of additional exemplary
embodiments of the
roofing shingle of the present invention, wherein one anterior tab has a first
breadth and three
anterior tabs have a second breadth.
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[00069] FIGS. 23-26 show top plan views of additional exemplary
embodiments of the
roofing shingle of the present invention, wherein three anterior tabs has a
first breadth and one
anterior tab has a second breadth.
DETAILED DESCRIPTION
[00070] The preferred embodiments of the present invention and its
advantages are
best understood by referring to FIGS. 1 through 26, like numerals being used
for like and
corresponding parts of the various drawings. The different shadings of the
individual layers in
the drawings are not intended to signify a particular color value or intensity
but only to indicate
color contrasts between the layers, and each individual layer may be lighter
or darker than the
shadings indicate; however a color contrast between the layers is optionally
employed.
[00071] The first embodiment of the present invention, which relates to
two-layer
composite roofing shingles having the appearance of variable thickness, will
now be described in
greater detail by referring to the drawings that accompany the present
application.
[00072] A shingle 10 incorporating one embodiment of the present
invention is shown
in FIGS. 1-4, 5 and 7. FIG. 1 illustrates a top plan view of shingle 10.
Shingle 10 has a width
(w) and a length (/). Shingle 10 comprises an anterior layer A and posterior
layer B. Shingle 10
further comprises a composite headlap 101 and a composite buttlap 102, wherein
when installed
on a roof deck, as illustrated in FIG. 7, at least a portion of the composite
headlap 101 of a
previously installed shingle 10 is covered by the composite buttlap 102 of a
subsequently
installed shingle 10.
[00073] FIGS. lA and 1B separately illustrate a top plan view of anterior
layer A and
posterior layer B, respectively. Referring to FIG. 1A, anterior layer A has a
width (wA) and a
length (/A). Anterior layer A comprises a headlap portion 1 and a buttlap
portion 2. The buttlap
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portion 2 comprises a plurality of anterior tabs 3 separated by anterior
openings 4. Each anterior
tab 3 has a breadth selected from at least two breadths 31, 32 and has a
height (hA). Preferably,
at least one anterior tab 3 has a first anterior tab breadth 31 and at least
another anterior tab 3 has
a second anterior tab breadth 32. Preferably, the first anterior tab breadth
31 may be between 1
and 5 inches, and more preferably, between 1 and 3 inches. Preferably, the
second anterior tab
breadth 32 may be between 5 and 10 inches, and more preferably, between 8 and
10 inches.
Preferably, the anterior tab height (hA) may be between 4 and 8 inches, and
more preferably,
between 6 and 8 inches. Preferably, each anterior tab height (hA) is the same
for each anterior
tab 3. Although FIG. 1A depicts anterior tabs 3 with the same anterior tab
height (hA), it is
contemplated that one or more anterior tabs 3 may have a different anterior
tab height (hA).
[00074] The anterior openings have breadths 41, 42. Preferably, at least
one anterior
opening 4 has a first anterior opening breadth 41 and at least another
anterior opening 4 has a
second anterior opening breadth 42. Preferably, the first anterior opening
breadth 41 may be
between 5 and 10 inches, and more preferably, between 8 and 10 inches.
Preferably, the second
anterior opening breadth 42 may be between 1 and 5 inches, and more
preferably, between 1 and
3 inches. In a particularly preferred embodiment, the first anterior tab
breadth 31 is equal to the
second anterior opening breadth 42 and the second anterior tab breadth 32 is
equal to the first
anterior opening breadth 41.
[00075] Preferably, anterior buttlap portion 2 comprises four anterior
tabs 3.
[00076] In one particularly preferred embodiment, the first anterior tab
breadth 31 is
about 2.88 inches and the second anterior tab breadth 32 is about 5.75 inches.
The anterior tab
height (hA) is about 7.00 inches. The first anterior opening breadth 41 is
about 5.75 inches and
the second anterior opening breadth 42 is about 2.88 inches.
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[00077] The anterior tabs 3 may be surfaced with mineral granules, which
may be
colored mineral granules. The anterior headlap portion 1 may also be surfaced
with mineral
granules, which may be colored mineral granules. The colored mineral granules
of the anterior
headlap portion 1 may be the same shade as the anterior tabs 3 or may be
different, i.e., the
anterior tabs 3 may have a first shade and the anterior headlap portion 1 may
have a second
shade.
[00078] Referring to FIG. 1B, posterior layer B has a width (-wB) and a
length (I3).
Posterior layer B comprises a headlap portion 11 and a buttlap portion 12. The
buttlap portion
12 comprises a plurality of posterior simulated tabs 13 separated by posterior
partial slots 271,
and each of the posterior simulated tabs 13 is connected to at least one
adjacent posterior
simulated tab 13 by a connecting segment 273. The posterior simulated tabs 13
have a breadth
131 and a height (hB). Preferably, the posterior simulated tab breadth 131 is
the same for each
posterior simulated tab 13 and may be between 4 and 10 inches, and more
preferably, between 7
and 9 inches. The posterior partial slots 271 have a breadth 141, which is
preferably the same for
each posterior partial slot 271 and may be between 1/8 and 3/4 inches, and
more preferably,
between 3/8 and 1/2 inches. The posterior partial slots 271 have a height
(h271), which preferably
may be between 50% and 90% of the height (hB) of the posterior simulated tabs
13, and more
preferably about 75% of the height (hB) of the posterior simulated tabs 13. [
[00079] Connecting segments 273 have a height (h273), which preferably
may be
between 1/4 and 1. 3/4 inches, and more preferably about 1 inch. The breadth
141 of a connecting
segment 273 is commensurate with the breadth 141 of the partial slot 271 above
the connecting
segment 273.
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[00080] Preferably, the number of posterior simulated tabs 13 is equal to
the number
of anterior tabs 3. In a particularly preferable embodiment, anterior layer A
comprises four
anterior tabs 3 and posterior layer B comprises four posterior simulated tabs
13. However,
embodiments with fewer than four anterior tabs 3 and four posterior simulated
tabs 13 are
contemplated, as well as embodiments with more than four anterior tabs 3 and
four posterior
simulated tabs 13.
[00081] In a particularly preferred embodiment, the posterior simulated
tab breadth
131 is about 8.25 inches and the posterior simulated tab height (hB) is about
7.5 inches. The
posterior partial slot breadth 141 is about 0.38 inches.
[00082] Preferably, the first anterior tab breadth 31 is less than 50%
the posterior
simulated tab breadth 131 and the second anterior tab breadth 32 is 50% or
more, but less than
100%, the posterior simulated tab breadth 131. In a particularly preferred
embodiment, the first
anterior tab breadth 31 is about 50% the second anterior tab breadth 32.
[00083] The posterior simulated tabs 13 are preferably surfaced with
mineral granules,
which may be colored mineral granules. Preferably, the colored mineral
granules of the posterior
simulated tabs 13 are a shade having a distinguishable hue or color from the
first shade of the
anterior tabs 3, and may also be different from the second shade of the
anterior headlap portion
=
1. The contrast in shade between the posterior simulated tabs 13 and the
anterior tabs 3 can be
accentuated by varying the consistency of the weather resistant top coating,
e.g., the density
and/or size of granule deposition on either of these members. It will be
appreciated that a
contrast in shade between any portions or regions of the inventive shingle can
similarly be
achieved by the methods described herein. It should be noted that the shading
of the colored
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mineral granules is not a necessary element of the present invention and
therefore any shading
scheme is appropriate.
[00084] Referring to FIGs. 1, 1A, and 1B, the exposed top outer surface
or weather
surface, i.e., the composite buttlap 102 of shingle 10 of the invention may be
coated with various
types of mineral granules to protect the asphalt coating, to add color to
shingle 10 of the
invention, and to provide fire resistance. A wide range of mineral colors from
white and black to
various shades of red, green, brown and any combination thereof may be used on
shingle 10 of
the invention to provide a roof having the desired color. In some embodiments,
the entire top
outer surface of shingle 10 of the invention may be coated with any of the
aforementioned
coatings. In further embodiments, the entire top surface of anterior layer A
may be coated with
coatings that contrast with coatings applied to the entire top surface of
posterior layer B. In
another embodiment, the top surface of anterior headlap 1 of shingle 10 of the
invention may be
coated with coatings that contrast with coatings applied to the top surface of
anterior tabs 3 and
posterior layer B. In another embodiment, the top surface of anterior headlap
1 may be coated
with coatings that contrast with coatings applied to the top surface of
anterior tabs 3 and also
contrast with coatings applied to the entire top surface of posterior layer B.
In another
embodiment, the top surface of anterior headlap 1 may be coated with coating
that contrast with
coatings applied to the posterior simulated tabs 13 and a portion of the
posterior headlap 11 that
may be exposed. The underside of shingle 10 of the invention may be coated
with various inert
minerals with sufficient consistency to seal the asphalt coating. These
modifications may be
applied to any contemplated embodiment of the invention in any combination.
[00085] FIGS. 1 and 5 depict shingle 10 with the anterior layer A
positioned on the
posterior layer B in a manner such that each anterior tab 3 is positioned over
a corresponding
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posterior simulated tab 13, wherein the anterior tabs 3 are positioned off-
center of the posterior
simulated tabs 13.
[00086] FIGS. 2 and 3 illustrate front elevation and rear elevation views
of shingle 10,
respectively, with the anterior layer A positioned on the posterior layer B in
a manner such that
the left and right side edges of both layers are flush, respectively.
[00087] FIG. 4 illustrates a right side view of shingle 10 with anterior
layer A
positioned on the posterior layer B in a manner such that the front and rear
edges of both layers
are offset, respectively. Referring back to FIG. 1, this offset positioning
results in a gap (g), or
an exposed top portion of each posterior simulated tab 13, between the front
edge of the posterior
simulated tab 13 and the front edge of the corresponding anterior tab 3.
Preferably, gap (g) is
between 0 and 1 inches, and more preferably, between 3/8 and 3/4 inches.
Referring to FIGS.
1 A and 1B, in a preferred embodiment, width of the anterior layer A (WA) is
about equal to the
width of the posterior layer B (wB). In a particularly preferred embodiment,
width of the anterior
layer A (wA) is greater than the width of the posterior layer B (wB). See FIG.
4A. It is further
contemplated that the width of the anterior layer A (wA) may be less than the
width of the
posterior layer B (wB). See FIGS. 4B and 4C.
[00088] Referring to FIGS. 1, 1A, and 1B, it will be appreciated that
when the width
of the anterior layer A (wA) is about equal the width of the posterior layer B
(wB) and the anterior
tab height (hA) is about equal to the posterior simulated tab height (hB) any
offset resulting in a
gap (g) will also result in a portion of the posterior headlap 11 being
exposed to the elements as
part of the composite buttlap 102. In other words, in such an embodiment, a
portion of the
posterior headlap 11, along with the posterior buttlap 12 and anterior buttlap
2 will operate as the
exposed composite buttlap 102 of shingle 10.
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[00089] Exemplary shingle 10 further comprises anterior layer A, wherein
each
anterior tab 3 has right angle corners and each anterior opening 4 has right
angle corners.
Alternatively, in another embodiment, shingle 60 having posterior simulated
tabs 64, depicted
in FIG. 6, the anterior tabs 63 have crimped comers (i.e., cut at
approximately 45 degree
angles) and the anterior openings have crimped corners (i.e., cut at
approximately 45 degree
angles). It is contemplated that the crimped comers may be cut at any suitable
angle for a
desired appearance. It should be noted that similar modifications can be done
independently
to the posterior simulated tabs 13 and remain within the scope of the
invention. In other
words, it is contemplated that the posterior simulated tabs 13 may have right
angle corners.
See shingles 90 and 100 depicted in FIGS. 9 and 10, respectively.
[00090] Exemplary shingle 10 further comprises anterior tabs 3 and
anterior
openings 4 having straight edges. It is contemplated, however, that the edges
of the anterior
tabs 3 and anterior openings 4 may have non-straight, irregular edges. See
shingle 110
depicted in FIG. 11. Referring to FIG. 8, it is also contemplated that the
edges of the anterior
tabs 83 of shingle 80 may have "stair-stepped" edges. It is further
contemplated that the edges
of the anterior tabs 3 may be trapezoidal (i.e., wider at the top or bottom of
the tab), angular
(i.e., the bottom of the tab may be cut at a slant rather than perpendicularly
straight across),
curved, or jagged. It should be noted that these modifications to the anterior
tabs 3 may also
be done to the posterior simulated tabs 13 in any contemplated combination and
remain within
the scope of the invention.
[00091] FIGS. 14-26 illustrate top plan views of additional exemplary
embodiments 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250 and
260,
respectively, of the two-layer shingle of the invention, wherein each
embodiment has at least
one anterior tab with a first breadth and at least another anterior tab with a
second breadth.
[00092] FIG. 7 depicts a particularly preferred roofing system
embodiment of the
present invention, wherein shingles 10, 140, 150 of the invention are
installed as they would
be
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applied to a roof deck, such that a part of the headlap portion 101 of a
previously installed course
of shingles lies beneath a part of the buttlap portion 102 of a subsequently
installed course of
shingles. As depicted in FIG. 7, five separate courses of shingles 10, 140,
150 are installed as
they would be in an offset manner. In a particularly preferred embodiment,
anterior tabs 3 create
a pattern (i.e., a "tab pattern") that spans a course of three adjacent
shingles 10, 140, 150,
wherein an anterior tab pair 5 (having the second anterior tab breadth 32) is
adjacent to another
anterior tab pair 6 having the first anterior tab breadth 31, but the first
and second subsequent
adjacent anterior tabs 7 have different tab breadths from each other. This tab
pattern repeats
itself across the span of the course, which creates a pleasing aesthetic
appearance that resembles
more expensive roofing material, such as tile, slate, or wood shakes. The
pattern of the anterior
tabs provides a seemingly random appearance that provides the illusion of
texture and variation
inherent in individual pieces of more expensive roofing materials. The visual
appearance of the
shingles may be further enhanced by methods well-known in the art, e.g.,
employing shadow tips
or shadow bands. In a further preferred embodiment, the shingles have an
anterior tab pattern
with at least two tabs of different breadth and at least two openings of
different breadth and the
shingles have a posterior layer with simulated tabs having a uniform breadth,
i.e., each posterior
simulated tab has the same breadth.
100093] In other preferred embodiments, the shingles of the invention
may further be
deployed in a roofing system, wherein first, second, and third adjacent
shingles differ from each
other based on the arrangement of the anterior tabs with different breadths
(see, e.g., FIG. 7 and
shingles 10, 140, 150), and wherein the first adjacent shingle and the fourth
adjacent shingle in a
course are identical based on the arrangement of the anterior tabs with
different breadths (see,
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e.g., FIG. 7), so that when installed, a pattern of varying anterior tabs is
created based on the
location of the anterior tabs with different breadths.
[00094] The shingles of the invention may further be deployed in a
roofing system,
wherein first, second, third, fourth, and fifth adjacent shingles differ from
each other based on
the arrangement of the anterior tabs with different breadths, and wherein the
first adjacent
shingle and the sixth adjacent shingle in a course are identical based on the
arrangement of the
anterior tabs with different breadths, so that when installed, a pattern of
varying anterior tabs is
created based on the location of the anterior tabs with different breadths.
1000951 The shingles of the invention may further be deployed in a
roofing system,
wherein first, second, third, fourth, fifth, and sixth adjacent shingles
differ from each other based
on the arrangement of the anterior tabs with different breadths, and wherein
the first adjacent
shingle and the seventh adjacent shingle in a course are identical based on
the arrangement of the
anterior tabs with different breadths, so that when installed, a pattern of
varying anterior tabs is
created based on the location of the anterior tabs with different breadths.
[00096] The shingles of the invention may further be deployed in a
roofing system,
wherein first, second, third, fourth, fifth, sixth, and seventh adjacent
shingles differ from each
other based on the arrangement of the anterior tabs with different breadths,
and wherein the first
adjacent shingle and the eighth adjacent shingle in a course are identical
based on the
arrangement of the anterior tabs with different breadths, so that when
installed, a pattern of
varying anterior tabs is created based on the location of the anterior tabs
with different breadths.
[00097] It is further contemplated that odd numbered adjacent shingles,
i.e., first, third,
fifth, etc., adjacent shingles are identical to each other based on the
arrangement of the anterior
tabs with different breadths and differ from even numbered adjacent shingles,
i.e., second,
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fourth, sixth, etc., adjacent shingles, based on the arrangement of the
anterior tabs with different
breadths, and wherein the even numbered adjacent shingles are identical to
each other based on
the arrangement of the anterior tabs with different breadths.
[00098] Not being limited to any particular theory, the aesthetically
pleasing and
seemingly random appearance of a particularly preferred embodiment of the
installed shingles of
the invention may result from the arrangement of anterior tabs and anterior
openings having the
same breadth, wherein said anterior openings appear to be voids where said
anterior tabs should
be situated. See FIG. 7, feature 8. The void of said anterior tabs may create
a visual illusion of
missing anterior tabs, which may resemble prior art shingles that have
utilized the absence of
anterior tabs to create the appearance of bulk and randomness of more
expensive roofing
materials. See, e.g, U.S. Pat. No. 7,805,905. It should be noted, however,
that unlike the prior
art shingles, each of the posterior simulated tabs of the shingles of the
invention is at least
partially covered by an anterior tab. Also, the visual appearance of the
anterior tab pattern may
further be enhanced by the uniform posterior simulated tab pattern, wherein
the partial slots
between the simulated tabs provide the visual appearance of increased
thickness to the buttlap
portion of the shingle.
[00099] An exemplary non-limiting method of manufacturing the inventive
shingle
embodiments is described with reference to the two-layer composite shingle.
[000100] Manufacturing the two-layer composite shingle includes applying
granules to
asphalt coated sheeting, where the granules can be blended to produce the
desired shading and
then applied to the surface of the asphalt sheet. The granule laden asphalt
sheet is then pressed
in a press roll unit, such that the granules embed in the asphalt coating. The
asphalt sheet is then
cut to the desired shape. The cutting process first measures out one shingle
length of material
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and then feeds the measured amount into the cutting module. The cutting module
preferably
includes a rotary cutting cylinder with hardened steel tooling. The tab
pattern of anterior layer A
is cut using a fractional cutting cylinder, where the fractional cutting
cylinder produces a pattern
that is a fraction of the shingle length. This provides a substantially
repeating pattern.
[000101] The shingles of the invention may be cut using a cutting cylinder
having a
diameter which is a portion of the shingle length (e.g. a cutting cylinder
diameter 1.5 times the
length of the shingle). The cutting cylinder may be designed such that the
pattern of posterior
simulated tabs 13 may or may not be cut at a greater frequency than the
pattern of anterior tabs 3.
[000102] For example, a fractional cutting cylinder with a pattern and a
circumference
that is 1.5 times the length of a single shingle may produce three distinct
shingles every two
rotations. Such a pattern will repeat itself every fourth shingle. In a
preferred embodiment the
pattern extends across the entire cutting cylinder. By utilizing a fractional
cutting cylinder
circumference, the maximum amount of patterns for the minimum amount of
diameter can be
produced. The preferred cylinder circumference is between about 1.25 and about
1.75 greater
than the length of a single shingle. A cutting cylinder that is 1.25 times the
shingle length may
produce five distinct shingles per four rotations, while a cutting cylinder
with a circumference
that is 1.75 times the shingle length may produce seven distinct shingles per
four rotations. In a
most preferred embodiment, a cutting cylinder having a pattern and a
circumference that is 1.5
times the length of shingle 10 is used to cut each anterior layer A for each
shingle 10. The
posterior layer B is preferably cut using a non-fractional cylinder pattern.
[000103] Referring back to FIG. 7, the exemplary shingles 10, 140, 150
were formed
with a cutting cylinder having a circumference that is 1.5 times the length of
shingle 10, 140,
150, which creates three distinct anterior layers. The pattern of the cutting
cylinder can be seen
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across the anterior layer of shingle 10 and half of the anterior layer of
shingle 140. The pattern
repeats and continues across the other half of the anterior layer of shingle
140 and the anterior
later of shingle 150. The sequence of anterior tabs repeats after the third
shingle. Such a pattern
and sequence of anterior tabs of this particularly preferred embodiment helps
convey a random
appearance.
[000104] Following cutting, the posterior layer B and anterior layer A are
joined. In
broad terms, preferably, an adhesive is applied to the posterior layer B
and/or anterior layer A,
wherein following the application of the adhesive the posterior layer B and
anterior layer A are
pressed together. The pressed posterior layer B and anterior layer A are then
cut to a
predetermined shingle length.
[000105] Preferably, the present invention also allows for a reduction in
material waste
during manufacturing compared to the manufacturing of prior art shingles.
Prior art tabbed two-
layer shingles have created the appearance of randomness and thickness of more
expensive
roofing material by providing at least one tab that is only one layer thick or
single-layer tabs (i.e.,
the posterior tabs that are not covered by an anterior tab). Such prior art
shingles utilize an
anterior layer with tabs, wherein each anterior tab has the same breadth and
the anterior tabs are
positioned substantially over the center of the posterior tabs, which have a
wider breadth than the
anterior tabs. See U.S. Pat. No. 7,805,905. Despite cutting complementary
anterior layers from
a single layer of roofing material, the process creates scraps between the
anterior tabs. The
present invention minimizes scrap material by utilizing the entire (or nearly
the entire) amount of
single layer of roofing material apportioned for the formation of the anterior
layers.
[000106] As depicted in FIG. 12, complementary prior art anterior layers
121 and 122
are cut from a shingle sheet of roofing material 120. For the prior art
embodiment illustrated,
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each anterior layer has two anterior tabs 123. When the anterior layers 121
and 122 are
positioned over a four-tabbed posterior layer (not shown) according to U.S.
Pat. No. 7,805,905,
each anterior layer will have two anterior tabs missing resulting in two
posterior tabs that are
uncovered by an anterior tab (not shown). The formation of anterior layers 121
and 122 from the
single sheet of roofing material 120 results in the cutting of scraps 124. Due
to the shape and
configuration of the prior art anterior tabs 123, waste roofing material is
created. Elements 121'
and 122' represent partial views of additional material portions to be cut
from roofing material
120 that will form additional anterior layer pieces.
[000107] Contrary to prior art methods, the anterior tabs of the present
invention have
differing breadths, which allows for the use of the entire sheet (or nearly
the entire sheet, e.g., if
anterior tabs have crimped corners) of roofing material to form two
complementary anterior
layers A, as illustrated in FIG. 13. FIG. 13 is a schematic depicting how two
complementary
anterior layers A (represented by material portions 131 and 132, respectively)
are cut from a
single layer of roofing material 130 and aligned with posterior layers B and
B' to form two
exemplary shingles 10. It will be appreciated that anterior layers A
(represented by material
portions 131 and 132, respectively) have anterior tabs with differing breadths
that are present in
complementary patterns that utilize the entire length of roofing material 130.
Thus, when
anterior layers A are formed from a sheet of roofing material according to the
invention few or
no scraps are generated. It will be further appreciated that the posterior
layer B' intended to form
a second shingle 10 has been shifted to the right in order to conceptualize
the proper alignment
of posterior layer B' with respect to anterior layer A (represented by
material portions 132) to
form a second shingle 10. Elements 131' and 132' represent partial views of
additional material
portions to be cut from roofing material 130 that will form additional
anterior layer pieces.
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[000108] For one embodiment of the present invention, the shingle 10 may
be formed
from a fiberglass mat (not shown) with an asphalt coating on both sides of the
mat. If desired,
the present invention may also be used with shingles formed from organic felt
or other types of
base material, including but not limited to synthetic mats or synthetic
glass/hybrid mats having
an appropriate coating. Nonlimiting embodiments of coatings include asphalt
and modified
bituminous coatings based on atactic polypropylene (APP), styrene-butadiane-
styrene (SBS),
styrene-ethylene-butadiene-styrene (SEBS), amorphous polyalpha olefin (APAO),
thermoplastic
polyolefin (TPO), synthetic rubber or other asphaltic modifiers.
[000109] Additional embodiments include laminated tabbed shingles with
three or more
layers (not shown) as long as at least one simulated tab is partially one
layer thick or a partially
covered single-layer simulated tab, and no simulated tabs are entirely one
layer thick.
[000110] An important feature of the present invention includes providing
roofing
shingles having posterior simulated tabs that are each partially covered by an
anterior tab. Prior
art two-layer, or bilaminated, shingles with posterior tabs that are not at
least partially covered by
an anterior tab are susceptible to wind failure. In particular, the prior art
single-layered tabs (i.e.,
posterior tabs without at least partial cover from anterior tabs) are
susceptible to wind failure
upon installation (prior to sealing) and even after the shingles have been
sealed. Applicants have
surprisingly found that two-layer shingle tabs have improved wind failure
resistance over single-
layer shingle tabs before the shingles have been sealed and even after the
shingles have been
sealed.
[000111] Test l: Applicants prepared prior art shingles having single-
layer tabs and
prior art shingles having double-layer tabs. Test samples were conditioned at
73 F (meaning
bundles of shingles were placed in a climate controlled environment to allow
the temperature to
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reach a steady state of 73 F) and then applied to a test deck, wherein the
test samples were not
allowed to fully seal to the test deck or to adjacent shingles (meaning
testing began shortly after
the shingles were installed on the test deck before a proper bond could be
achieved between the
shingles and the test deck or adjacent shingles). Wind resistance testing was
performed on the
test samples, wherein a wind generator was directed at the installed test
samples and the wind
speed was incrementally increased until shingle tabs lifted from the test
deck. Results are
provided in Table 1 below.
Table 1
Wind Speed Single-layer Double-layer
(MPH) Tabs Lifted Tabs Lifted Comments
Multiple single layer teeth lifted immediately at
40 X the start of the test.
60
Multiple double layer teeth started to lift at 19
X
minutes.
10001121 Test
2: Applicants prepared prior art shingles as in Test 1 (i.e., conditioned at
conditioned at 73 F). The shingles were then installed on a test deck (i.e.,
a substrate surface) at
an ambient temperature of 73 F. The test deck was then conditioned at 140 F
for 16 hours to
allow the sealant to bond (i.e., the sealant between the shingle and substrate
surface was allowed
to form a proper bond), then the test deck was conditioned back to an ambient
temperature of 73
F prior to testing. Mechanical uplift resistance testing was performed on the
test samples,
wherein the substrate surface was held down while the test apparatus measured
the resistance (in
lbs) necessary to peel away a shingle tab from the substrate surface. Results
are provided in
Table 2 below.
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Table 2
Mechanical Uplift Resistance (lbs)
Sample Thickness
Single Double
1 28.32 30.87
2 22.91 42.45
3 22.87 23.07
4 22.89 27.32
Average 24.25 30.93
[000113] It was believed that fully sealed test shingle tabs, whether
single-layer or
double-layer, would exhibit similar wind failure resistance because the bond
strength of the
sealant would dictate performance. However, in Test 2, Applicants have
surprisingly found that
the two-layered tabs had improved wind failure resistance (measured as
mechanical uplift
resistance) compared to the single-layer tabs even though both sets of tabs
were fully sealed to
the substrate surface. The uplift resistance of the sealed double-layer tab
was 28% greater than
the sealed single-layer tab.
[000114] Another important feature of the present invention includes
providing a
connecting segment 273. In addition to the weather performance imparted by the
above-tested
features (e.g., partially covered tabs), it is believed that connecting
segment 273 will provide
increased rigidity to single-thickness posterior simulated tabs (which
resemble traditional,
discrete tabs) thereby further improving the shingle's wind failure resistance
compared to the
prior art.
[000115] Although the present invention and its advantages have been
described in
detail, it should be understood that various changes, substitutions and
alterations can be made
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therein without departing from the spirit and scope of the invention as
defined by the appended
claims.
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