AESTHETIC, SELF-ALIGNING SHINGLE FOR HIP, RIDGE, OR RAKE PORTION OF A ROOF

Abstract

There is provided a hip, ridge, or rake shingle, which includes a shingle panel and at least one rigid back member. The shingle panel has a substantially planar lower surface. The at least one rigid back member has a length substantially the same as or greater than the length of the shingle panel. The rigid back member is attached to the substantially planar lower surface of the shingle panel. The rigid back member includes a step in thickness in a cross-sectional plane perpendicular to the substantially planar lower surface and parallel to the longitudinal axis of the rigid back member. In addition, the thickness of the rigid back member at the high level of the step is greater than the thickness of the rigid back member at one of its ends. There is also provided an asphaltic adhesive including from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.

Description

BACKGROUND

[0001] The present invention relates generally to the construction of a shingle for covering the hip, ridge, or rake portion of a roof. In particular, the present invention relates to the construction of a hip, ridge, or rake shingle having a thick, aesthetic appearance and a self-aligning mechanism for the rapid and uniform installation of a number of such shingles.

[0002] In the roofing art, it is well-known to attempt to enhance the appearance of a non-wood hip, ridge, or rake shingle by increasing the height of such a shingle to simulate the height of a wood shingle. Examples of such shingles are provided in U.S. Pat. Nos. 5,471,801; 5,377,459; 5,247,771; and 3,913,294. In addition, another example of such a shingle is provided by the Z-Ridge® shingle product sold by Elk Corporation of Ennis, Tex. These shingles are constructed using creative folding designs for the shingle web material to create an overall shingle appearance that is thicker than that of the web material alone.

[0003] While these shingles provide an improved appearance over unfolded or flat shingles, they all suffer from common deficiencies. First, all of the shingles are difficult to align while installing and, thus, require great care in installation to avoid unsightly irregular appearances. Second, when installed, the shingles produce an exaggerated “saw-tooth” appearance, which is different than the more level appearance of wood shingles. Third, the shingles are difficult (if not impossible, in some cases) to install over “ridge vent” products (to be discussed below). Moreover, even in the best case, installation is a two-step process: the “ridge vent” products are nailed in place, followed by the installation of the ridge shingles. Finally, with time and heat, the folds in the shingles tend to compress and the shingles tend to droop and lose their wood-like appearance.

[0004] It is an object of the present invention to provide a hip, ridge, or rake shingle that overcomes these deficiencies.

SUMMARY OF THE INVENTION

[0005] According to the present invention, there is provided a hip, ridge, or rake shingle, which includes a shingle panel and at least one rigid back member. The shingle panel has a substantially planar lower surface and an upper surface. The back member has a length that is substantially the same as or greater than the length of the shingle panel. The back member is attached to the substantially planar lower surface of the shingle panel. The back member includes a step in thickness in a cross-sectional plane perpendicular to the substantially planar lower surface and parallel to the longitudinal axis of the back member. In addition, the thickness of the back member at the high level of the step is greater than the thickness of the back member at one of its ends.

[0006] Preferably, the shingle panel is composed of an asphalt material and the upper surface of the shingle panel includes a granular material thereon. Preferably, the composition of the shingle panel further includes a rubberized material. The rubberized material is preferably a styrene-butadiene-styrene block copolymer. Preferably, the back member is composed of an injection-molded thermoplastic. Alternatively, the back member may be composed of any rigid material suitable for outdoor exposure, such as molded recycled tire rubber, metal, or wood. If a thermoplastic is used, the back member may include from about 40% to 70% filler by weight.

[0007] Preferably, the back member includes a trapezoid-shaped base and a plurality of walls extending from the base. The step in thickness of the back member is provided by a step in the height of the walls in a cross-sectional plane perpendicular to the base and parallel to the longitudinal axis of the back member.

[0008] For installation with “ridge vent” systems (to be discussed below), the back member preferably includes channels formed therein communicating between a side of the back member and an area near the longitudinal center axis of the shingle panel. Preferably, the channels are formed in a zig-zag or herringbone pattern. Through the channels, the shingle according to the present invention is able to vent the air escaping through the ridge vent of the roof to the outside environment.

[0009] In yet another preferred embodiment of the invention, the back member includes a planar base surface that is attached to the substantially planar lower surface of the shingle panel. Opposite the planar base surface, the back member includes a surface inclined with respect to the planar base surface and a surface parallel to the planar base surface. At the juncture between the inclined surface and the parallel surface, there is formed the step in thickness of the back member. In this embodiment, the back member preferably includes cavities formed therein. The cavities lighten the back member, but at the same time do not substantially impair the rigidity of the back member.

[0010] According to another aspect of the present invention, the back member is attached to the shingle panel using a novel asphaltic adhesive. The asphaltic adhesive includes from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.

[0011] The grade of the asphalt cement may be any of the grades specified by the American Society for Testing and Materials in Tables 1 to 3 of Publication D3381-92, entitled “Standard Specification for Viscosity-Graded Asphalt Cement for Use in Pavement Construction.” A blend of different grades of asphalt cement may be used.

[0012] Preferably, the grade of the asphalt cement is AC-30 or below. In addition, it is preferred that the first thermoplastic is a styrene-butadiene-styrene block copolymer having a butadiene/styrene ratio in the range of about 68/32 to about 84/16, a block polystyrene in the range from about 30% to 32%, and an oil content in the range of from about 4.5 phr to 5.5 phr. It is also preferred that the second thermoplastic is a styrene-isoprene-styrene (SIS) block polymer or a latex having a molecular weight in the range of about 100,000 to about 100 million atomic units. The latex may be of a wide variety, including anionic latex, cationic latex, and a combination thereof. Preferably, the latex comprises a styrene-butadiene rubber polymer having from about 62% to about 70% polymer solids in water, a pH in the range of about 5.25 to about 10.5, and a monomer ratio of butadiene to styrene in the range from about 74/26 to about 78/22.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which:

[0014] FIG. 1 is an isometric view of a shingle according to a preferred embodiment of the present invention;

[0015] FIG. 2 is a bottom plan view of a shingle according to the embodiment of FIG. 1;

[0016] FIG. 3 is a side plan view of a shingle according to the embodiment of FIG. 1;

[0017] FIG. 4 is a top plan view of a back member of a shingle according to the embodiment of FIG. 1;

[0018] FIGS. 5 and 6 are side plan views of a shingle according to the embodiment of FIG. 1;

[0019] FIG. 7 is an isometric view of the placement of a series of shingles after installation, each shingle constructed according to the embodiment of FIGS. 1 to 6;

[0020] FIG. 8 is a side plan view of a pair of shingles according to another preferred embodiment of the present invention;

[0021] FIG. 9 is an isometric view of a back member of a shingle according to another preferred embodiment of the present invention;

[0022] FIG. 10 is a bottom plan view of a shingle including a back member according to the embodiment of FIG. 9;

[0023] FIG. 11 is a side plan view of a shingle according to the embodiment of FIG. 10;

[0024] FIG. 12 is an isometric view of a back member according to the embodiment of FIG. 9;

[0025] FIG. 13 is a bottom plan view of a shingle according to another preferred embodiment of the present invention;

[0026] FIG. 14 is a side plan view of a back member of a shingle according to the embodiment of FIG. 13; and

[0027] FIG. 15 is a side plan view of a shingle according to the embodiment of FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

[0028] FIG. 1 is an isometric view of a shingle 5 according to a preferred embodiment of the present invention. The shingle 5 includes a shingle panel 10 and a back member 20, which is attached to the bottom surface 12 (see FIG. 2) of the shingle panel 10. The shingle panel 10 may be in the form of any symmetrical shape, such as a rectangle or a trapezoid. As shown in FIGS. 1 and 2, however, the shingle panel 10 is preferably trapezoid shaped because a trapezoid shape has been found to yield the best general appearance when the shingle 5 is installed.

[0029] The shingle panel 10 is composed of an asphalt material. Preferably, to enhance its flexibility and bending strength, the shingle panel 10 is composed of a fiberglass-based SBS-modified asphalt material, where SBS represents a styrene-butadiene-styrene block copolymer. As is well-known in the art, the upper surface 14 of the shingle panel 10 (the surface facing away from the roof when the shingle is installed) contains granular ceramic material embedded therein (not shown).

[0030] The back member 20 may be attached to the shingle panel 10 by any suitable asphaltic adhesive. According to one aspect of the present invention, the back member 20 is preferably attached to the shingle panel 10 by a novel asphaltic adhesive comprising from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a high glass-transition temperature (Tg); and from about 0.5% to about 15% by weight of a second thermoplastic having a low glass-transition temperature (Tg). A preferred range for each of said first and second thermoplastics is from about 1% to about 7% by weight.

[0031] As used in this specification and the appended claims, a high glass-transition temperature refers to a glass-transition temperature in the range from about 190° F. to about 260° F. and a low glass-transition temperature refers to a glass-transition temperature in the range from about −55° F. to about 0° F. The glass-transition temperature, as known to those skilled in the art, refers to the temperature above which a polymer exhibits liquid-like properties. Advantageously, by combining a thermoplastic with a high glass-transition temperature and a thermoplastic with a low glass-transition temperature, the asphaltic adhesive of the present invention provides excellent adhesive performance in both high temperatures and low temperatures. Thus, the asphaltic adhesive is suitable for a wide variety of geographic locations, including those locations having wide seasonal temperature variations.

[0032] As used in this specification and the appended claims, asphalt cement refers to vacuum distillation bottoms. The grade of the asphalt cement that may be used in the present invention includes any of the grades specified by the American Society for Testing and Materials (“ASTM”) in Tables 1 to 3 of Publication D3381-92, entitled “Standard Specification for Viscosity-Graded Asphalt Cement for Use in Pavement Construction”, which is incorporated herein by reference. A blend of different grades of asphalt cement may also be used. Preferably, the grade of the asphalt cement is AC-30 or below, as defined by the ASTM in Publication D3381-92. The requirements for asphalt cement of grade levels AC-30 and below are given in Table 1.

TABLE 1
Requirements for Asphalt Cement of Grades AC-30 and Below
	Viscosity Grades
Test	AC-2 5	AC-5	AC-10	AC-20	AC-30
Viscosity, 140° F. (60° C.), P	250 ± 50	500 ± 100	1000 ± 200	2000 ± 400	3000 ± 600
Viscosity, 275° F. (135° C.), min, cSt	125	176	250	300	350
Penetration, 77° F. (25° C.), 100 g, 5 s, min	220	140	80	60	50
Flash point, Cleveland open cup, min, ° F. (° C.)	325 (163)	350 (177)	425 (219)	450 (232)	450 (232)
Solubility in trichloroethylene, min, %	99 0	99 0	99 0	99 0	99 0
Tests on residue from thin-film oven heat
Viscosity, 140° F. (60° C.), max, P	1250	2500	5000	10000	150000
Ductility, 77° F. (25° C.), 5 cm/min, min, cm	100a	100	75	50	40
aIf ductility is less than 100, material will be accepted if ductility at 60° F. (15.5° C.) is 100 minimum at a pull rate of 5 cm/min

[0033] The thermoplastic having a low glass-transition temperature may be a latex. The latex may be of a wide variety, including anionic latex, cationic latex, and a combination thereof, having a molecular weight in the range from about 100,000 to about 100 million atomic units. Examples of latex that may be used in the asphaltic adhesive of the present invention include butyl rubber latex, styrene-butadiene rubber latex, neoprene latex, polyvinyl alcohol emulsion latex, water-based polyurethane emulsion latex, water-based polyurethane elastomer latex, vinyl chloride copolymer latex, nitrile rubber latex, or polyvinyl acetate copolymer latex.

[0034] Preferably, the latex is a high molecular weight, high mooney viscosity styrene-butadiene rubber polymer latex that has the properties specified in Table 2.

TABLE 2
Latex Properties
Property                         Range of Values
Total Solids, % by weight        62-70
pH                               5.25-10.5
Viscosity (Brookfield), cps      800-1650
Monomer Ratio (Butadiene/Styrene) 74/26-78/22
Pounds/Gallon Ratio              7.7-8.1

[0035] Alternatively, instead of latex, the thermoplastic with the low glass-transition temperature may be a linear styrene-isoprene-styrene (SIS) block polymer, such as KRATON® D1107 thermoplastic, which is manufactured and sold by Shell Chemicals Ltd.

[0036] Preferably, the thermoplastic with a high glass-transition temperature is a styrene-butadiene-styrene (SBS) block copolymer having the properties specified in Table 3. The methods referred to in the last column of Table 3 are methods published by the American Society for Testing and Materials. Examples of SBS thermoplastics that be may used for the thermoplastic with the high glass-transition temperature include thermoplastics sold under the brand names KRATON® D1101 (manufactured and sold by Shell Chemicals Ltd.), FINA 409 (manufactured and sold by Fina Oil and Chemical Co.), and FINA 411 (manufactured and sold by Fina Oil and Chemical Co.).

TABLE 3
Styrene-Butadiene-Styrene (SBS) Properties
Property	Range of Values	Method
Melt Flow at 180° C./5 kg (g/10	0.1-1.0	ASTM D-1238
min)
Tensile Strength (psi)	2300-4600	ASTM D-638
Elongation at break (%)	550-820	ASTM D-638
300% modulus (psi)	240-800	ASTM D-638
Shore A Hardness	71-82	ASTM D-2240
Butadiene/Styrene Ratio	68/32-84/16
Block Polystyrene (%)	30-32
Oil Content (phr)	4.5-5.5
Specific Gravity at 23° C. (g/cm3)	0.92-0.95
Refractive Index	1.44-1.64
Viscosity of 5.2% Toluene	4-20
Solution (cSt)
Color	White
Form	Crumb and/or
	Powder

[0037] Table 4 lists specific adhesive formulations in accordance with the present invention. It is noted that the percentages used in Table 4 are by weight of the asphaltic adhesive. These formulations are hot-melt adhesives, which are applied at temperatures of between 300 degrees and 400 degrees F.

TABLE 4
Specific Adhesive Formulations
	Formulations
Compound	Manufacturer	1	2	3	4	5	6	7	8
GB AC-20	Golden Bear,	91.7%	90.9%		94.3%	91.7%	92.2%	92.6%	91.7%
	Bakersfield, CA
GB AC-5	Golden Bear,			91.2%
	Bakersfield,
	CA
UP-70 Latex	UltraPave,	1.4%	1.4%	1.3%			1.4%	0.9%	1.4%
SBR	Dalton, GA,
(Styrene-	La Mirada, CA
butadiene
Rubber)
UP-2897 Latex	UltraPave,				1.0%
	Dalton, GA,
	La Mirada, CA
KRATON	Shell Chemicals					2.8%
D1107	Ltd.
(Styrene-
isoprene
styrene)
Fina 409 SBS	FINA Oil and	6.9%	7.7%		4.7%	5.5%	6.4%	6.5%
(Styrene-	Chemical Co.,
butadiene-	Carville, LA
styrene)
Fina 411 SBS	FINA Oil and			7.5%					6.9%
(Styrene-	Chemical Co.,
butadiene-	Carville, LA
styrene)

[0038] Of the formulations listed in Table 4, formulations 1, 5, 7, and 8 are preferred based on adhesive performance as determined by a SLUMP test using 15-18 mil thick layers of the adhesive formulations. If cost-effectiveness of the formulations is taken into account, the preferred formulation is formulation 7. If expense is not a factor, formulation 5 is preferred overall because of its performance, ease of processing, ease of blending, and ease of storage.

[0039] Table 5 lists certain physical properties of the formulations of Table 4, where experimental data for these formulations was available. The physical properties listed in Table 5 are merely exemplary and are not intended to convey representative values. Indeed, as indicated by the data for two different samples of formulation 1, the properties in Table 5 may vary widely due to the variability in the properties of asphalt cement, even when the asphalt cement is of the same grade and obtained from the same manufacturer. The variation in these properties, however, does not greatly effect the adhesive performance of the formulations.

TABLE 5
Physical Properties of Formulations (Final Blend)
	Formulations
Physical	1	1
Properties	(Sample 1)	(Sample 2)	2	3	4	5	6	7	8
Viscosities
(centipoise)
350 F.	608						560	510
360 F.		1162	1667	1767
380 F.		845	1182	795
400 F.	399	630	907	540			373	315
450 F.	234						218	180
Softening Point (F.)	215	221	231	214		197	208	210
Penetration (mm)	38.2	35.0	31.0	41.0				40.1

[0040] The mixing procedure for the formulations shown in Table 4 includes, first, heating the asphalt cement in a mixing tank to a temperature of between 325° F. to 375° F. Second, the SBS rubber is added to the asphalt cement, and the blend is mixed for about 45 to 120 minutes, until all of the SBS rubber is swelled and no rubber particles are observable. Next, the latex or the SIS thermoplastic material is added to the blend at a temperature of 350° F. If latex is added, caution should be used in adding the latex because the temperature of the blend will cause the water in the latex to evaporate or bubble out. Moreover, latex should be added very slowly to the hot blend as adding the latex too rapidly could splash the blend or could allow the blend to climb up on the mixing stirrer. On complete addition of the latex, the blend is mixed for about 30 minutes. The blend is then ready to use.

[0041] The mixing procedure has been described with reference to a mixing tank. Alternatively, instead of a tank, the mixing may also be performed by injecting the materials through in-line piping, as is well-known by those skilled in the art.

[0042] Cross-linking agents, from about 0.1% to about 2.5% by weight, may also be added to the formulations in Table 4. A preferred range for the cross-linking agents is 0.1% to 0.2% by weight. The addition of cross-linking agents allows less SBS to be used in each formulation; however, it also degrades the low-temperature performance of the asphaltic adhesive.

[0043] If cross-linking agents are to be added to the blend, the cross-linking agents are added after the latex or the SIS thermoplastic material is mixed in. After adding the cross-linking agents, the blend is mixed for about four hours at a temperature of 350° F. to 380° F. Examples of suitable cross-linking agents that may be used in the present invention include the agents sold under the brand names BUTAPHALT 720 (sold by Texpar Energy, Inc., Waukesha, Wis.), HVA-2 (sold by E. I. du Pont de Nemours and Company, Wilmington, Del.), and TETRONE (sold by E. I. du Pont de Nemours and Company, Wilmington, Del.).

[0044] If latex is used in the asphaltic adhesive, it is noted that water will evaporate out of the latex over time and the polymers in the latex may cross-link with each other. Accordingly, if the asphaltic adhesive includes latex, the asphaltic adhesive will become thicker and more viscous over time.

[0045] The back member 20 is preferably manufactured from an injection-molded thermoplastic material, such as injected-molded polystyrene, polypropylene, or polyethylene. The polystyrene, polypropylene, or polyethylene materials may be low, medium, or high density and may be used with 40% to 70% filler by weight. Such filler may include limestone, gypsum, aluminum trihydrate (ATH), cellulose fiber, and plastic polymer fiber. Other thermoplastic materials that may be used include ethylene-vinyl-acetate (EVA) polymer materials, ethylene-mythylene-acrylate (EMAC) materials, neoprene materials, and polychlorosulfonated polymer (Hypalon) materials.

[0046] Although an injection-molded thermoplastic material is preferred for the manufacture of the back member 20, any rigid material suitable for outdoor exposure is also suitable. For example, molded recycled tire rubber, metal, or wood may also be used. If rubber is used, it is preferred that amine be added to each of the adhesive formulations in Table 4. Up to 5% amine by weight may be added, but because amine's odor is unpleasant, the addition of 0.1% to 0.2% amine by weight is preferred.

[0047] FIG. 2 is a bottom plan view of the shingle 5 of FIG. 1. As shown in FIG. 2, the base 25 of the back member 20 is also trapezoid-shaped, having substantially the same length as the shingle panel 10. For example, if the shingle panel 10 has a length of 13¼ inches, the back member may be 13 inches long. The back member 20 is attached to the shingle panel 10 such that the longitudinal center axis 11 of the shingle panel 10 and the longitudinal center axis 21 of the base 25 are aligned. In addition, the short edge 13 of the shingle panel 10 and the short edge 23 of the base 25 are also aligned. For the purposes of this specification, the end of the shingle 5 including the short edges of the shingle panel 10 and base 25 will be referred to as the trailing end, and the opposite end of the shingle 5 will be referred to as the front end.

[0048] The back member 20 has two side walls 22a and 22b extending from the base 25 along the base's longitudinal edges. The back member 20 also has eight longitudinal walls 24 extending from the base 25, which are parallel to the longitudinal axis 21 of the base 25, and eight transverse walls 26a-26h extending from the base 25, which are perpendicular to the longitudinal axis 21 of the base 25. Two of the transverse walls 26a and 26e are disposed along the front edges of the base 25.

[0049] The transverse walls 26a-26h are divided into two sets of four walls, which are disposed on opposite sides of the longitudinal center axis 21 of the base 25. The first set includes walls 26a-26d, and the second set includes walls 26e-26h. In addition, wall 26a is disposed opposite wall 26e; wall 26b is disposed opposite wall 26f; wall 26c is disposed opposite wall 26g; and wall 26d is disposed opposite wall 26h. The opposing walls are offset from each other along the longitudinal center axis 21 by an amount A sufficient to ensure that they do not interfere with each other when the shingle 5 is folded—i.e., they are offset from each other by an amount greater than the width of each wall. To facilitate the folding of the shingle 5, the back member 20 preferably has a slit 27 in the base 25 along its longitudinal center axis 21. The base 25 also has rectangular holes 28 in the areas between some of the longitudinal walls 24 and the transverse walls 26a-26h. The holes 28 limit the twists and deformation of the base 25 under heat.

[0050] FIG. 3 is a side plan view of the shingle 5 of FIG. 1, viewed along an axis perpendicular to the longitudinal center axis 11 of the shingle panel 10. As shown in FIG. 3, the side wall 22a of the back member 20 is composed of a wedge-shaped section 29a and a rectangular section 29b. Transverse wall 26b is positioned at the juncture between sections 29a and 29b. At the juncture of the wedge-shaped section 29a and rectangular section 29b, there is a step in the height of the side wall 22a—i.e., the height of the wedge-shaped section 29a is greater than the height of section 29b.

[0051] Side wall 22b is identical to sidewall 22a. At any point along the longitudinal axis of the back member 20, the height of each of the longitudinal walls 24 and the transverse walls 26a-26h corresponds to the height of the sidewalls 22a and 22b at that longitudinal position.

[0052] FIG. 4 is a top plan view of the back member 20. The top surface of the base 25 is preferably corrugated, with the corrugations running longitudinally along the base 25. The corrugations facilitate the adherence of the back member 20 to the shingle panel 10. FIGS. 5 and 6 are side plan views of the back member 20 viewed along axes parallel to the longitudinal center axis 21 of the back member 20. FIGS. 5 and 6 further illustrate the features of the back member 20 discussed above.

[0053] FIG. 7 is an isometric view of the placement of a series of shingles 5a, 5b, and 5c after installation on a hip, ridge, or rake portion of a roof. Each of the shingles 5a, 5b, and 5c is a shingle according to the embodiment of FIGS. 1 to 6, with the shingle panel 10 folded along its longitudinal center axis 11 (see FIG. 2) to form an inverted V-shape with the back member 20 inside of the shingle panel 10. To begin the installation, shingle 5a is placed on the hip, ridge, or rake portion of the roof and installed by nailing or other suitable means. Shingle 5b is then placed on top of shingle 5a, with the front end of shingle 5b placed on the trailing end of shingle 5a. The front end of shingle 5b is then slid toward the front end of shingle 5a until the step of the back member 20 of shingle 5b engages the edges at the trailing end of shingle 5a. Shingle 5b is then nailed or otherwise suitably fastened in place on the roof. Shingle 5c is installed in the same manner over shingle 5b.

[0054] As will be appreciated by those skilled in the art, shingles according to the present invention provide the following benefits. First, the step of the back member 20 allows the shingles to be easily aligned with each other for a quick and uniform installation. Second, the thickness of the back member 20 enhances the appearance of the shingles and provides a wood-like look to the shingles. Third, since the back member 20 is substantially the same length as the shingle panel 10, the thickness of each shingle is enhanced across its entire length, and the shingles thereby avoid an exaggerated “saw-tooth” appearance after installation. Finally, since the back member 20 of each shingle is made of a rigid material, the shingles will not droop over time or under heat and lose their thick, wood-like appearance.

[0055] FIG. 8 is a side plan view of a pair of shingles 100a and 100b according to another preferred embodiment of the present invention. Each of the shingles 100a and 100b includes a shingle panel 110 and a back member 120 similar to the shingle panel 10 and back member 20, respectively, of FIGS. 1 to 6. A difference between the back member 120 of FIG. 8 and the back member 20 of FIGS. 1 to 6 is that the step of the back member 120 is angled so that when the shingles 100a and 100b are installed, the shingles 100a and 100b interlock with one another.

[0056] FIGS. 9 to 12 illustrate a shingle 200 according to another preferred embodiment of the present invention, which incorporates a ventilation function for “ridge vent” systems. Presently, many homes are constructed such that the peak of a roof has an opening of approximately two inches along its length. This opening is covered by a special “ridge vent” material that allows air to pass out of the home, but prevents insects and moisture from entering into the home. The “ridge vent” material is then covered by standard ridge shingle products. Clearly, a two-step process is currently necessary for the installation of shingles on homes using a “ridge vent” system.

[0057] FIG. 9 is an isometric view of a back member 220 according to a preferred embodiment of the present invention, and FIG. 10 is a bottom plan view of the back member 220. As in the previous embodiments, the back member 220 includes a trapezoid-shaped base 225. The base 225 includes a slit 227 along its longitudinal center axis 221 to facilitate the folding of the back member 220.

[0058] Six transverse walls 226a-226f extend from the base 225 and run in a direction perpendicular to the longitudinal center axis 221 of the base 225. The transverse walls 226a-226f are divided into two sets of three walls, which are disposed on opposite sides of the longitudinal center axis 221. The first set includes walls 226a-226c, and the second set includes walls 226d-226f. In addition, wall 226a is disposed opposite wall 226d; wall 226b is disposed opposite wall 226e; and wall 226c is disposed opposite wall 226f. The opposing walls are offset from each other along the longitudinal center axis 221 by an amount A sufficient to ensure that they do not interfere with each other when the shingle 200 is folded—i.e., they are offset from each other by an amount greater than the width of each wall.

[0059] Between the trailing edge of the base 225 and the transverse walls 226c and 226f, four walls 224 parallel to the longitudinal center axis 221 of the back member 220 extend from the base 225. In addition, in this area, there are disposed two side walls 222 extending from the longitudinal edges of the base 225.

[0060] Between the transverse walls 226a and 226c and the transverse walls 226d and 226f, there are disposed a plurality of channel walls 230 extending from the base 225. The channel walls 230 are preferably arranged in a zig-zag or herringbone pattern and form channels communicating between the sides of the back member 220 and the central portion of the back member 220 (the area around the longitudinal center axis 221 of the back member 220). In addition, along the longitudinal edges of the base 225, there are disposed pins 232 extending from the base 225. Preferably, the pins 232 are spaced apart so that the width of each of the openings along the sides of the back member 225 is less than {fraction (1/4)} inch.

[0061] When a shingle 200 with back member 220 is placed on a ridge vent roof, the air being vented from the ridge of the roof passes through the channels formed by the channel walls 230 and into the outside environment. Advantageously, the zig-zag or herringbone pattern of the channel walls 230 prevents the entry of water into the ridge vent by forcing the water to take a tortuous path through the back member 220. In addition, the pins 232 prevent the penetration of insects into the back member 220 by restricting the width of the openings in the sides of the back member 220. Accordingly, the installation of ridge vent material underneath the shingle 200 is not necessary, and only a one-step installation process is necessary to install shingles according to this embodiment on a ridge vent roof.

[0062] FIG. 11 is a side plan view of the back member 220, showing the back member 220 includes the same step feature as the back member 20 of FIGS. 1 to 6. Dividing the back member 220 into two sections 229a and 229b for the purposes of discussion (with the transverse wall 226e serving as the partition between the two sections), the walls in section 229a increase in height along the longitudinal axis of the back member 220 from the trailing edge of the base 225 to the transverse wall 226e. In section 229b, all of the walls have the same height, which is less than that of the transverse wall 226e. The difference in height between the walls in section 229a and the walls in section 229b provides the step in thickness of the back member 220.

[0063] FIG. 12 is an isometric view of the back member 220. The top surface of the base 225 is preferably corrugated, with the corrugations running longitudinally along the base 225. The corrugations facilitate the adherence of the back member 220 to the shingle panel 210.

[0064] As shown in FIGS. 9, 10, and 12, between the trailing edge of the base 225 and the transverse walls 226c and 226f, there are disposed a plurality of circular holes 228 in the base 225. If the shingle panel 210 is made shorter than the base 225 (not shown), the holes 228 provide a further of means of ventilation for the air escaping the ridge vent of the roof.

[0065] FIG. 13 is a bottom plan view of a shingle 300 according to another preferred embodiment of the present invention. The shingle 300 includes a shingle panel 310 having attached thereto two back members 320a and 320b. The back members 320a and 320b are mirror images of each other and are placed on the shingle panel 310 in symmetrical relation with respect to the longitudinal center axis 311 of the shingle panel 310.

[0066] FIG. 14 is a side plan view of back member 320a, viewed from an axis perpendicular to the longitudinal center axis 311 of the shingle panel 310. (The corresponding side plan view of back member 320b is the same.) The back member 320a includes a planar base surface 325a, which is attached to the shingle panel 310. Opposite the planar base surface 325a, the back member has a planar surface 324a that is inclined with respect to the base surface 325a and a planar surface 326a that is parallel to the base surface 325a. At the juncture between the surfaces 324a and 326a, the height of surface 324a is greater than the height of surface 326a, thereby producing a step in the thickness of the back member 320a. The back members 320a and 320b preferably include a plurality of rectangular-shaped cavities 328a and 328b therein, respectively, which lighten the back members and reduce the material needed to construct them.

[0067] FIG. 15 is a side plan view of shingle 300, viewed from the front end along an axis parallel to the longitudinal center axis 311 of the shingle panel 310. The back member 320a has side walls 321a and 322a, and the back member 320b has side walls 321b and 322b. The side walls of each back member 320a and 320b are angled inwardly with respect to each back member 320a and 320b. The angling of side walls 322a and 322b is necessary to ensure that these side walls do not interfere with each other when the shingle panel 310 is folded.

[0068] Although the present invention has been described with reference to certain preferred embodiments, various modifications, alterations, and substitutions will be apparent to those skilled in the art without departing from the spirit and scope of the invention, as defined by the appended claims.

Claims

1. A hip, ridge, or rake shingle comprising: a shingle panel having a substantially planar lower surface and an upper surface; and at least one rigid back member having a length substantially the same as or greater than the length of said shingle panel and attached to said substantially planar lower surface of said shingle panel, said at least one rigid back member having a step in thickness in a cross-sectional plane perpendicular to said substantially planar lower surface and parallel to the longitudinal axis of said at least one rigid back member, the thickness of said at least one rigid back member at the high level of said step being greater than the thickness of said at least one rigid back member at an end of said at least one rigid back member.

2. The hip, ridge, or rake shingle of claim 1, wherein said shingle panel is composed of an asphalt material and said upper surface of said shingle panel includes a granular material thereon.

3. The hip, ridge, or rake shingle of claim 2. wherein said shingle panel further comprises a rubberized material.

4. The hip, ridge, or rake shingle of claim 3, wherein said rubberized material is a styrene-butadiene-styrene block copolymer.

5. The hip, ridge, or rake shingle of claim 1, wherein said at least one rigid back member includes a trapezoid-shaped base and a plurality of walls extending from said base, said walls having a step in height in a cross-sectional plane perpendicular to said base and parallel to the longitudinal axis of said at least one rigid back member, said step in height of said walls providing said step in thickness of said at least one rigid back member.

6. The hip, ridge, or rake shingle of claim 5, wherein said plurality of walls includes first and second sets of walls disposed on opposite sides of and perpendicular to the longitudinal center axis of said at least one rigid back member.

7. The hip, ridge, or rake shingle of claim 6, wherein each wall in said first set of walls and a corresponding wall in said second set of walls are offset from each other along the longitudinal center axis of said at least one rigid back member by an amount greater than the width of each wall.

8. The hip, ridge, or rake shingle of claim 5, wherein said base includes corrugations on the surface to be attached to said substantially planar lower surface of said shingle panel.

9. The hip, ridge, or rake shingle of claim 5, wherein said base includes a slit along its longitudinal center axis for facilitation of folding of said at least one rigid back member.

10. The hip, ridge, or rake shingle of claim 1, wherein said step is capable of interlocking with an end of a shingle which is substantially identical to said hip, ridge, or rake shingle.

11. The hip, ridge, or rake shingle of claim 1, wherein said at least one rigid back member includes channels formed therein communicating between a side of said at least one rigid back member and an area near the longitudinal center axis of said shingle panel, whereby when said shingle is installed on a ridge vent roof, said channels allow ventilation of the roof to the outside environment.

12. The hip, ridge, or rake shingle of claim 11, wherein said channels are arranged in a zig-zag or herringbone pattern.

13. The hip, ridge, or rake shingle of claim 11, wherein the width of the openings of said channels along the sides of said at least one rigid back member is less than or equal to {fraction (1/4)} inch.

14. The hip, ridge, or rake shingle of claim 11, wherein said at least one rigid back member includes a trapezoid-shaped base and a plurality of walls extending from said base, said plurality of walls forming said channels.

15. The hip, ridge, or rake shingle of claim 14, wherein said at least one rigid back member includes a plurality of pins extending from the longitudinal edges of said base.

16. The hip, ridge, or rake shingle of claim 1, wherein said at least one rigid back member includes a planar base surface that is attached to said substantially planar lower surface of said shingle panel, a surface inclined with respect to said planar base surface, and a surface parallel to said planar base surface; and wherein said step in thickness of said at least one rigid back member is formed at the juncture of said inclined surface and said parallel surface.

17. The hip, ridge, or rake shingle of claim 16, wherein said at least one rigid back member includes cavities formed therein.

18. The hip, ridge, or rake shingle of claim 1, wherein said at least one rigid back member is composed of an injection-molded thermoplastic material.

19. The hip, ridge, or rake shingle of claim 18, wherein said thermoplastic material is selected from the group consisting essentially of polystyrene, polypropylene, polyethylene, ethylene-vinyl-acetate (EVA), ethylene-mythylene-acrylate (EMAC), neoprene, and polychlorosulfonated polymer (Hypalon).

20. The hip, ridge, or rake shingle of claim 19, wherein said at least one rigid back member further includes from about 40% to about 70% filler by weight.

21. The hip, ridge, or rake shingle of claim 20, wherein said filler is selected from the group consisting essentially of limestone, gypsum, aluminum trihydrate, cellulose fiber, and plastic polymers fiber.

22. The hip, ridge, or rake shingle of claim 1, wherein said at least one rigid back member is composed of a material selected from the group consisting essentially of molded recycled tire rubber, metal, and wood.

23. An asphaltic adhesive for use with roofing material, comprising: from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.

24. The asphaltic adhesive of claim 23, comprising from about 1% to about 7% by weight of said first thermoplastic and from about 1% to about 7% by weight of said second thermoplastic.

25. The asphaltic adhesive of claim 23, wherein said first thermoplastic is a styrene-butadiene-styrene block copolymer.

26. The asphaltic adhesive of claim 25, wherein said styrene-butadiene-styrene block copolymer has a butadiene/styrene ratio in the range of about 68/32 to about 84/16, a block polystyrene in the range from about 30% to 32%, and an oil content in the range of from about 4.5 phr to 5.5 phr.

27. The asphaltic adhesive of claim 23, wherein said second thermoplastic is a styrene-isoprene-styrene block polymer.

28. The asphaltic adhesive of claim 23, wherein said second thermoplastic is a latex having a molecular weight in the range of about 100,000 to about 100 million atomic units.

29. The asphaltic adhesive of claim 28, wherein said latex comprises a styrene-butadiene rubber polymer.

30. The asphaltic adhesive of claim 29, wherein said styrene-butadiene rubber polymer comprises from about 62% to about 70% polymer solids in water, has a pH in the range of about 5.25 to about 10.5, and has a monomer ratio of butadiene to styrene in the range from about 74/26 to about 78/22.

31. The asphaltic adhesive of claim 23, wherein the grade of said asphalt cement is AC-30 or below.

32. The asphaltic adhesive of claim 23, further comprising from about 0.1% to about 2.5% by weight of one or more cross-linking agents.

33. The asphaltic adhesive of claim 23, further comprising from about 0.1% to 5.0% by weight of amine.

34. A method of producing an asphaltic adhesive, comprising the steps of: heating an asphalt cement to a temperature of between 325° F. to 375° F.; mixing into said asphalt cement a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and mixing into the blend of said asphalt cement and said first thermoplastic a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.; wherein said blend of asphalt cement, first thermoplastic, and second thermoplastic comprises from about 62% to about 99% by weight of said asphalt cement; from about 0.5% to about 15% by weight of said first thermoplastic; and from about 0.5% to about 15% by weight of said second thermoplastic.