The present disclosure relates generally to roofing shingles and methods for installing them. The present disclosure relates more particularly to multi-layered roofing shingles having overlapping side butt joints.
The two most common types of bituminous (e.g., asphalt) roofing shingles are three-tab shingles and architectural or “laminated” shingles. Three-tab shingles are generally formed from a single bituminous sheet having an exposure zone and a headlap zone, with three distinct “tabs” defined by two elongated notches between the tabs. The notches extend from a bottom edge of the shingle, through at least part of the exposure zone toward the headlap zone. The shingles are laid in lateral rows on a roof in an edge-to-edge manner. To prevent the infiltration of water between the joints formed where the sides of two adjacent shingles meet, the exposure zones of an upper row of shingles are generally installed over the headlap zones of a lower row of shingles, in a repeating pattern where the joints are laterally staggered between rows. Due to this headlap requirement, the headlap zone of a traditional shingle has a height that is greater than the height of the exposure zone.
Architectural shingles also generally include an exposure zone and a headlap zone. The exposure zone of an architectural shingle is typically composed of a top bituminous sheet that includes tabs (e.g., so-called “dragon's teeth”) that cover respective portions of a continuous bottom bituminous sheet. The headlap zone is typically composed solely or mostly of the top bituminous sheet. The top and bottom sheets are laminated together to present a layered appearance. Due to the headlap requirement noted above, the relative sizes of the exposure zone and the headlap zone are generally the same as those noted above.
Accordingly, what is needed is an improved roofing shingle that provides similar protection from water infiltration but utilizes less material.
One aspect of the disclosure is a roofing shingle having a headlap zone disposed above an exposure zone, the roofing shingle including:
Another aspect of the disclosure is a roofing shingle system comprising:
Another aspect of the disclosure is a roof comprising a roof deck having an upper end and a lower end, and the roofing shingle system as described herein fastened thereto, the headlap zones of the roofing shingles being disposed toward the upper end of the roof deck and the exposure zones of the roofing shingles being disposed toward the lower end of the roof deck
Another aspect of the disclosure is a method for installing a roof as described herein. The method includes:
Another aspect of the disclosure is a method for making a roofing shingle as described herein. The method includes:
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
The present inventors have noted disadvantages of conventional roofing shingles. In particular, their substantial headlap requirement necessitates a shingle that is rather large for the exposed area that the shingle actually contributes to the roof. For example, a traditional shingle which may have a 6 inch exposure height requires another 6 inches of headlap height, and may require an additional 2 inches of overlap to ensure that the lateral joints between shingles are adequately protected from water infiltration.
The present inventors have noted that conventional architectural shingles generally have at least two shingle layers, which do not necessarily need to be positioned with their side edges aligned. Rather, the side edges of the top and bottom layers of an architectural shingle may be laminated together in a staggered arrangement such that, when two such shingles are abutted side by side, a shiplap joint is formed. Moreover, a single joint that extends all the way through both layers of two abutting shingles does not exist. Consequently, the traditional and substantial headlap between shingle layers is no longer needed, and the height of the headlap zone of the roofing shingle may be dramatically reduced.
Accordingly, one aspect of the disclosure is a roofing shingle having a first shingle layer and a second shingle layer which are laminated together in a laterally offset arrangement, such that the side edges of the first shingle layer and the second shingle layer overlap each other.
One embodiment of such a roofing shingle is described with respect to
As shown in
As noted above the roofing shingle 100 also includes a second shingle layer 201, which may be at least partially laminated to the top surface 104 of the first shingle layer 101, as shown in
The second shingle layer 201 may include a first side edge 207, which is the right side edge as shown in the example of
Further, the second shingle layer 201 may include a second side edge 208 that extends beyond the second side edge 108 of the first shingle layer 101 so as to overlap the second side edge 108 of the first shingle layer 101 by a second sidelap distance 112. In
Accordingly, the roofing shingle 100 may be abutted edge to edge with another roofing shingle 100 such that a shiplap joint is formed between the first and second shingle layers. The joint formed between the two first shingle layers will be positioned beneath one of the second shingle layers, and the joint formed between the two second shingle layers will be positioned over one of the first shingle layers. In this arrangement, neither joint provides a direct path for water to penetrate beneath the roofing shingle 100. As a result, the required height for the headlap zone 102 of the roofing shingle 100 may be substantially reduced.
In particular, unlike the traditionally abutted shingles discussed above, where the entire exposure zone of a given shingle must be placed atop the headlap zone of an adjacent shigle to account for the joints, the majority of the exposure zone 103 of the roofing shingle 100 can be placed directly on the roof deck, or on whatever underlayment is used. This may allow, for example, a height of the headlap zone 102 to be less than a height of the exposure zone 103, which is not possible in traditionally abutted shingles, as discussed above. In some embodiments as otherwise described herein, the headlap zone 102 may be no greater than, for example, 2 inches, while the height of the exposure zone 103 may be 4 inches or more. For instance, in some implementations, the exposure zone 103 may have a height of 8 inches or more, while the headlap zone 102 may be only 2 inches, to provide sufficient vertical overlap of the joint between adjacent siding courses.
Conventional shingle materials can be used in the roofing shingles of the present disclosure. In some examples, the first shingle layer 101 and the second shingle layer 201 may be formed from the same material. For example, the first shingle layer 101 and the second shingle layer 201 may be formed from respective fiberglass or felt mats that are coated with a bituminous coating (e.g., asphalt) and weather-resistant roofing granules. Such mats may be formed with other conventional materials known to one of ordinary skill in the art as well.
Further, the first shingle layer 101 may have a thickness that is equal to a thickness of the second shingle layer 201. For instance, in some implementations, the first shingle layer 101 and the second shingle layer 201 may be cut from the same fiberglass mat. In other examples, the two shingle layers may have the same thickness, but they may have different colors. In other examples, the first shingle layer 101 and the second shingle layer 201 may have different thicknesses.
In some implementations, the first sidelap distance 111 may be substantially the same as the second sidelap distance 112, such that the first shingle layer 101 and the second shingle layer 201 of the roofing shingle 100 will both abut the opposing first and second shingle layers of an adjacent roofing shingle 100. In some other embodiments, the second sidelap distance 112 may be greater than the first sidelap distance 111, or the second sidelap distance 112 may be less than the first sidelap distance 111.
In some embodiments as otherwise described herein, the bottom edge 106 of the first shingle layer 101 may be substantially coextensive with the bottom edge 206 of the second shingle layer 201. In other examples, such as the roofing shingle 100 shown in
Similarly, the top edge 105 of the first shingle layer 101 maybe substantially coextensive with the top edge 205 of the second shingle layer 201, as shown in
In some embodiments as otherwise described herein, the top shingle layer 201 may include a plurality of tabs formed in the exposure zone of the roofing shingle 100. The plurality of tabs, such as the plurality of tabs 209 shown in
In some implementations, the bottom edge 106 of the first shingle layer 101 may include one or more notches, such as the notches 110 shown in
In some embodiments as otherwise described herein, at least the first side edge 207 of the second shingle layer 201 may be disposed completely within the headlap zone 102, as shown in
As can be seen in
In some embodiments as otherwise described herein, the one or more gaps 210 may each have the same width 211, as shown in
Similarly, in some examples of the roofing shingle 100 discussed herein, each tab 209 in the plurality of tabs 209 may have the same width 212, as shown in
Turning now to
As noted above, the top end 205 of the second shingle layer 201 in
In addition, the bottom edge 105 of the first shingle layer 101 of the roofing shingle 100 shown in
In some embodiments as otherwise described herein, and as shown in the example roofing shingle 100 shown in
As noted above, the width 211 of each gap 210 of the roofing shingle 100 may be the same. For instance, with reference to the example roofing shingle 100 shown in FIG. 4, the width 211 of each gap 210 may be the same at the bottom edge 106 of the first shingle layer 101, and may vary at the same rate toward the headlap zone 102. Alternatively, the gap widths 211 may be varied within a given roofing shingle 100, not only in their starting width 100 at the bottom edge 105 of the first shingle layer 101, but also in the angle of one or both sides of a given gap 210. As noted above, this may provide an irregular pattern that may simulate the appearance of a cedar shake roof, which may be desirable in some cases.
Another embodiment of the disclosure is a roofing shingle system that includes a plurality of roofing shingles, such as the roofing shingle 100 as discussed in the examples above. For example,
For instance, the siding system 300 may include a first plurality of roofing shingles 100 arranged laterally edge to edge to form a first course 120. The first plurality of shingles may include a first roofing shingle 100a and a second roofing shingle 100b, as shown in
Further, the second side edge 208a of the second shingle layer 201a of the first roofing shingle 100a and the first side edge 207b of the second shingle layer 201b of the second roofing shingle 100b are abutted against each other to form a second butt joint 213. As shown in the example of
Accordingly, the roofing shingle system 300 may further include a second plurality of roofing shingles arranged laterally edge to edge to form a second course 220, For example, each roofing shingle in the second plurality of roofing shingles may be the roofing shingle 100 discussed in the examples above. Further, the second course 220 may be positioned such that an exposure zone 303 of each roofing shingle 100 in the second plurality of roofing shingles overlaps the headlap zone 102 of at least one of the roofing shingles 100 in the first plurality of roofing shingles in the first course 120. This pattern may then be repeated with a third plurality of roofing shingles arranged in a third course positioned to overlap the headlap zone 302 of the shingles in the second course 220, and so on.
Further,
In some embodiments as otherwise described herein, the roof 400 may include as underlayment a weather resistant barrier 404 positioned between the roof deck 401 and the roofing shingle system 300. In some applications, the weather resistant barrier 404 may be considered a part of the roofing shingle system 300, as indicated in
At block 502, the method 500 includes positioning the first roofing shingle, such as the first roofing shingle 100a shown in
At block 504, the method 500 includes positioning the second roofing shingle, such as the second roofing shingle 100b shown in
Further, the second roofing shingle 100b may be positioned such that the second side edge 208a of the second shingle layer 201a of the first roofing shingle 100a and the first side edge 207b of the second shingle layer 201b of the second roofing shingle 100b are abutted against each other to form a second butt joint 213.
At block 506, the method 500 may include fastening each shingle in the first plurality of roofing shingles, including the first roofing shingle 100a and the second roofing shingle 100b, to the roof deck 401 in a laterally edge-to-edge manner to form the first course, such as the first course 120 shown in
At block 508, the method 500 comprises fastening each roofing shingle in the second plurality of roofing shingles to the roof deck 401 in a laterally edge-to-edge manner to form the second course, such as the second course 220 shown in
At block 602, the method 600 includes positioning a second shingle layer, such as the second shingle layer shown in
Additionally or alternatively, the second shingle layer 201 may be positioned such that a second side edge 208 of the second shingle layer 201 extends beyond a second side edge 108 of the first shingle layer 101 so as to overlap the second side edge 108 of the first shingle layer 101 by a second sidelap distance 112, as discussed in the examples above.
At block 604, the method 600 includes at least partially laminating the second shingle layer 201 to the top surface 104 of the first shingle layer 101. For instance, before positioning the second shingle layer 201 in contact with the top surface 104 of the first shingle layer 101, the method 600 may include applying a laminating adhesive to the top surface 104 of the first shingle layer 101. The laminating adhesive may be, for example, a hot-melt adhesive or an asphaltic laminating adhesive, among other possibilities.
Conventional methodologies for shingle construction can be used in the manufacturing of the roofing shingles as described herein.
Additional aspects of the disclosure are provided by the following enumerated embodiments, which can be combined and permuted in any number and in any combination that is not technically or logically inconsistent.
A roofing shingle having a headlap zone disposed above an exposure zone, the roofing shingle comprising:
The roofing shingle of embodiment 1, wherein the bottom edge of the first shingle layer substantially coextensive with the bottom edge of the second shingle layer.
The roofing shingle of embodiment 1, wherein the bottom edge of the second shingle layers is offset from the bottom edge of the first shingle layer such that a bottom portion of the top surface of the first shingle layer is exposed.
The roofing shingle of any of embodiments 1-3, wherein the top edge of the first shingle layer is substantially coextensive with the top edge of the second shingle layer
The roofing shingle of any of embodiments 1-3, wherein the top end of the second shingle layer extends beyond the top edge of the first shingle layer so as to overlap the top edge of the first shingle layer.
The roofing shingle of any of embodiments 1-5, wherein the sidelap distance is at least 2 inches, e.g., at least 4 inches or at least 6 inches.
The roofing shingle of any of embodiments 1-6, wherein a height of the headlap zone is less than a height of the exposure zone.
The roofing shingle of any of embodiments 1-7, wherein a height of the headlap zone is no greater than 2 inches.
The roofing shingle of any of embodiments 1-8, wherein a height of the exposure zone is at least 4 inches, e.g., at least 6 inches, or at least 8 inches.
The roofing shingle of any of embodiments 1-9, wherein the first shingle layer and the second shingle layer are formed from the same material.
The roofing shingle of any of embodiments 1-10, wherein the first shingle layer has a thickness that is equal to a thickness of the second shingle layer.
The roofing shingle of any of embodiments 1-11, wherein the first shingle layer has a thickness that is different from a thickness of the second shingle layer.
The roofing shingle of any of embodiments 1-12, wherein the first sidelap distance is substantially equal to the second sidelap distance.
The roofing shingle of any of embodiments 1-13, wherein the second shingle layer comprises a plurality of tabs formed in the exposure zone of the roofing shingle, the plurality of tabs separated by one or more gaps extending from the bottom edge of the second shingle layer to the headlap zone of the roofing shingle.
The roofing shingle of embodiment 14, wherein the bottom edge of the first shingle layer comprises one or more notches, wherein each notch in the one or more notches is aligned with a respective gap in the second shingle layer.
The roofing shingle of any of embodiments 14-15, wherein at least the first side edge of the second shingle layer is disposed completely within the headlap zone, e.g., wherein both the first side edge of the second shingle layer and the second side edge of the second shingle layer are disposed completely within the headlap zone.
The roofing shingle of any of embodiments 14-16, wherein the second edge of the second shingle layer extends beyond the second edge of the first shingle layer such that one of the tabs in the plurality of tabs is positioned over the second edge of the first shingle layer.
The roofing shingle of any of embodiments 14-17, wherein the one or more gaps each comprise the same width.
The roofing shingle of any of embodiments 14-17, wherein each gap in the one or more gaps comprises a width that is different from a width of at least one adjacent gap.
Embodiment 20, The roofing shingle of any of embodiments 14-19, wherein each gap in the one or more gaps comprises a respective width of at least 0.5 inches, e.g., at least 1 inch, or at least 2 inches, or at least 4 inches.
Embodiment 21, The roofing shingle of any of embodiments 14-20, wherein each tab in the plurality of tabs comprises the same width.
The roofing shingle of any of embodiments 14-20, wherein each tab in the plurality of tabs comprises a width that is different from a width of at least one adjacent tab.
The roofing shingle of any of embodiments 14-22, wherein each tab in the plurality of tabs comprises a respective width of at least 1 inch, e.g., at least 2 inches, at least 4 inches, or at least 6 inches.
The roofing shingle of any of embodiments 14-23, wherein each gap in the one or more gaps comprises a respective width that increases from the bottom edge of the first shingle layer toward the headlap zone of the roofing shingle, such that each tab comprises a respective width that decreases from the bottom edge of the second shingle layer toward the headlap zone of the roofing shingle.
A roofing shingle system comprising:
The roofing shingle system of embodiment 25, wherein the first butt joint is positioned beneath the second shingle layer of the second roofing shingle such that the second shingle layer of the second roofing shingle substantially covers the first butt joint.
The roofing shingle system of any of embodiments 25-26, wherein the second butt joint is positioned substantially within the headlap zone of the first and second roofing shingles, such that the second butt joint is covered by the second course of roofing shingles.
A roof comprising a roof deck having an upper end and a lower end, and the roofing shingle system of any of embodiments 25-27 fastened thereto, the headlap zones of the roofing shingles being disposed toward the upper end of the roof deck and the exposure zones of the roofing shingles being disposed toward the lower end of the roof deck.
The roof of embodiment 28, further comprising a weather resistant barrier layer positioned between the roof deck and the roofing shingle system.
The roof of embodiment 29, wherein the weather resistant barrier comprises at least one of a bituminous mat, a woven synthetic mat, or a felt mat.
A method for installing a roof according to any of embodiments 28-30, the method comprising:
The method of embodiment 31, wherein fastening each roofing shingle to the roof deck comprises placing a fastener through the first shingle layer and the second shingle layer, and into the roof deck.
A method for making a roofing shingle according to any of embodiments 1-24, the method comprising:
The method of embodiment 33 further comprising:
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This application claims the benefit of priority of U.S. Provisional Patent Application No. 62/651,096, filed Mar. 31, 2018, which is hereby incorporated herein by reference in its entirety.
Number | Date | Country | |
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62651096 | Mar 2018 | US |