Patent Grant
9808947
The present application generally relates to roofing shingle systems and, more particularly, to roofing shingle systems incorporating two or more shingles with different shingle patterns.
Roofing materials, such as roofing shingles, are installed on the roofs of buildings to provide protection from the elements and to give the roof an aesthetically pleasing look. Two of the most common shingle styles offered in residential roofing are single layer, three-tab shingles and multilayer architectural or laminate shingles. Single layer, three-tab shingles generally include a single substrate constructed to be flat without any dimensional thickness and include three individual equal width tabs cut into the portion of the shingle that is exposed when installed on a roof.
Architectural or laminate shingles generally include two substrates laminated together with tabs of varying widths formed in the exposed area, and typically slightly different shades of color, to give a more dimensional appearance that is often considered more aesthetically pleasing than conventional three-tab shingles.
A roofing system including shingles with different shingle patterns. In one exemplary embodiment, the roofing system includes a plurality of first shingles having a first two-tab shingle pattern and a plurality of second shingles having a second two-tab shingle pattern. The first shingles including a first tab having a first width and a second tab having a second width, wherein the first width and the second width are substantially equal. The second shingles including a third tab having a third width and a fourth tab having a fourth width, wherein the third width is substantially equal to the first width and the fourth width is about double the second width. The plurality of first shingles and the plurality of second shingles can be formed from a rectangular shingle blank in an interwoven pattern with substantially no scrap or waste material.
In another exemplary embodiment, the roofing system includes a plurality of third shingles having a third two-tab shingle pattern. The third shingles including a fifth tab having a fifth width and a sixth tab having a sixth width, wherein the fifth width is substantially equal to the first width and the sixth width is about 1.5 times the second width.
Various objects and advantages will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings. It is to be expressly understood, however, that the drawings are for illustrative purposes and are not to be construed as defining the limits of the invention.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate some embodiments disclosed herein, and together with the description, serve to explain principles of the embodiments disclosed herein.
The embodiments disclosed herein will now be described by reference to some more detailed embodiments, in view of the accompanying drawings. These embodiments may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventions to those skilled in the art.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements. Every numerical range given throughout this specification and claims will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
As used in the description and the appended claims, the phrase “asphalt” is defined as any type of bituminous material suitable for use on a roofing material, such as asphalts, tars, pitches, or mixtures thereof. The asphalt may be either manufactured asphalt produced by refining petroleum or naturally occurring asphalt. The asphalt may include various additives and/or modifiers, such as inorganic fillers or mineral stabilizers, organic materials such as polymers, recycled streams, or ground tire rubber. Preferably, the asphalt contains asphalt and an inorganic filler or mineral stabilizer.
As used in the description of the invention and the appended claims, the term “longitudinal” or “longitudinally” is defined as substantially parallel with the machine direction. The terms “top” and “bottom”, when used regarding the roofing material, are in reference to the roofing material when installed on a roof “Bottom” referring to the portion facing towards the roof deck and “top” referring to the portion facing away from the roof deck.
The substrate 102 is then fed to a coater 114 where a hot asphalt coating 116 is applied to the substrate. The asphalt coating 116 may be applied in any suitable manner, such as, for example, sprayed, rolled or pumped onto the substrate 102. In an exemplary embodiment, the asphalt coating 116 is a conventional filled asphalt used on asphalt based shingles. In the exemplary embodiment, the asphalt coating 116 is applied to the substrate 102 prior to a pair of rollers 120 such that as the substrate 102 moves between the nip point of the two roller configuration 120, the rollers completely cover the substrate 102 with the asphalt coating 116 to form a first asphalt coated sheet 122. The asphalt coating 116 impregnates and saturates the substrate 102 and may form an asphalt layer on the top side 108 and the bottom side 110 of the substrate 102.
Next, the asphalt coated sheet 122 is passed beneath one or more granule dispensers 124 that apply granules 126 to the top side 108 of the asphalt coated sheet 122 to form a granule coated sheet 130. The granule dispensers 124 can be of any type suitable for depositing granules onto the asphalt coated sheet 122 and the granules can be any granulates suitable for use with roofing material. The granules 126 may be applied to the entire top side 108 of the asphalt coated sheet 122 or selectively to portions of the sheet.
The granule-coated sheet 130 is then turned around a slate drum 132 to press the granules 126 into the asphalt coating and to temporarily invert the sheet so that the excess granules will fall off and will be recovered and reused. After the granule-coated sheet 130 is turned around the slate drum 132, a backing agent (not shown), such as sand, may optionally be applied to the bottom side 108 of the granule-coated sheet 130 to the extent that the bottom side becomes entirely encapsulated. Release film (not shown) may optionally be applied to the bottom side 110 of the granule-coated sheet 130 while the sheet wraps around the slate drum 132 and prior to the application of the backing agent.
The granule-coated sheet 130 may also pass through a set of press rolls 134 to complete the embedment of the granules 126 into the filled asphalt coating and through a series of cooling steps after the press rolls and prior to being cut. The granule-coated sheet 130 is subsequently passed into contact with one or more rotary pattern cutters 136 that cut the granule-covered sheet 130 into individual, single-layer (substrate) shingles. Thus, the granule-covered sheet 130 acts as a parent sheet for the shingles formed from it.
The first lane 206 of cut shingles and a second lane 208 of cut shingles are interwoven so that substantially no material from the granule-coated sheet 130 is scrap or waste. For the purpose of this disclosure, “substantially no scrap or waste material” refers to the interwoven shingle patterns utilizing substantially all of the granule-coated sheet material as part of the patterns. In other words, the perimeter of each shingle follows the perimeter of an adjacent shingle or forms an edge of the granule-coated sheet. Scrap or waste material, however, does not include material that would be removed, if any, by the rotary cutter as the cutter cuts along the perimeter of the shingle patterns, or excess material at the terminal end of a granule-coated sheet, or material discharged due to imperfections in the sheet or miscuttings, or similar circumstances resulting in the shingle not be deemed suitable for use.
Referring to
Referring to
The tab portion 406 includes a series of alternating tabs and cutouts. The tab portion 406 may include any number of alternating tabs and cutouts. In the illustrated embodiment, the tab portion 406 of the second shingle 204 includes a first cutout 408 having a width W1C2, a first tab 410 having a width W1T2, a second cutout 412 having a width W2C2, and a second tab 414 having a width W2T2. In the exemplary embodiment, the first cutout width W1C2, the second cutout width W2C2, and the first tab width W1T2 are substantially equal with the second cutout 412 bisecting a centerline C2 of the second shingle 204. The second tab 414 has a width W2T2 that is about double (2×) the width W1T2 of the first tab 410, but in other embodiments, the second tab width W2T2 can be more than about double the first tab width W1T2 or less than about double the first tab width. The second shingle 204 does not include a third cutout similar to the third cutout 316 of the first shingle 202. In one exemplary embodiment, the first tab width W1T1 of the first shingle 202 is substantially equal to the first tab width W1T2 of the second shingle; however, in other embodiments, the first tab width W1T1 of the first shingle 202 may be greater or less than the first tab width W1T2 of the second shingle. Additionally, in one exemplary embodiment, the first cutout width W1C1 of the first shingle 202 is substantially equal to the first cutout width W1C2 of the second shingle; however, in other embodiments, the first cutout width W1C1 of the first shingle may be greater or less than the first cutout width W1C2 of the second shingle.
In the exemplary embodiment, the height of each of the cutouts 408, 412 and each of the tabs 410, 414 is equal to the tab portion height HT2. In other embodiments, however, each cutout and tab may have different heights. The second shingle 204 also includes a left edge 430 and a right edge 432. Left and right referring to the orientation of the first shingle as illustrated in
In an exemplary embodiment, the narrowest tab width of the shingle is substantially equal to one-fifth (20%) of the total width of the shingle. As an example, the width W1T2 of the first tab 410 of the second shingle 204 may be substantially equal to one fifth of the width W2 of the second shingle (e.g. W1T2=W2/5) and the width W2T2 of the second tab 414 may be two-fifths (40%) of the width W2 of the second shingle or double the width W1T2 of the first tab 410.
The width W1 of the first shingle 202 and the width W2 of the second shingle 204 may vary in different embodiments of the shingle system 200. Any suitable shingle width may be used. For example, in one exemplary embodiment, the first shingle 202 may have a width W1 of approximately 40 inches, a height H1 of about 13.25 inches, and the widths W1C1, W2C1, W3C1 of each of the cutouts 308, 312, 316 and the widths W1T1, W2T1 of each of the tabs 310, 314 may be approximately 8 inches. In another exemplary embodiment, the first shingle 202 may have a width W1 of approximately 39.375 inches and the widths W1C1, W2C1, W3C1 of each of the cutouts 308, 312, 316 and the widths W1T1, W2T1 of each of the tabs 310, 314 may be approximately 7.875 inches.
In an exemplary embodiment, the shingle system 200, the first shingle 202 has a width W1 of about 39.375 inches, a height H1 of about 13.25 inches, a head portion height HH1 of about 7.625 inches, a tab portion height of about 5.625 inches, and width of about 7.875 inches for each of the cutouts 308, 312, 316 and tabs 310, 314.
The exemplary embodiment of the roofing shingle system 200 is designed such that each course can include a random series of first shingles 202 and second shingles 204 arranged side-by-side while always having a tab of a shingle in a subsequent course overlay the edge joint 510 between two shingles in the previous course. The amount that the tab of a shingle in a subsequent course horizontally overlaps the edge joint 510 between two shingles in the previous course is referred to as sidelap SL. The amount that a shingle in a subsequent course vertically overlaps the head portion 304, 404 of the shingles in the previous course is referred to as headlap HL. During installation, as long as one shingle in the subsequent course is positioned such that a tab from that shingle overlays the edge joint in the previous course, preferably with a sidelap SL of about half the width of the narrowest tab, then the edge joints in the underlaying course will always be covered by a tab from the overlaying course, regardless of which shingles, or the order of the shingles, are laid.
For example, the first course 504, from left to right in
As shown in
The headlap HL in the shingle system 200 may vary in different embodiments of the shingles. For example, in an exemplary embodiment in which the shingles have a width W1 of approximately 40 inches and a height H1 of about 13.25 inches, the headlap HL may be approximately 2 inches.
Referring to
The tab portion 614 includes a series of alternating tabs and cutouts. The tab portion 614 may include any number of alternating tabs and cutouts. In the illustrated embodiment, the tab portion 614 of the third shingle 606 includes a first cutout 618 having a width W1C3, a first tab 620 having a width W1T3, a second cutout 622 having a width W2C3, a second tab 624 having a width W2T3, and a third cutout 626 having a width W3C3. In the exemplary embodiment, the first cutout width W1C3, the second cutout width W2C3, and the first tab width W1T3 are substantially equal with the second cutout 622 bisecting a centerline C3 of the third shingle 606.
The second tab 624 has a width W2T3 that is about one-and-one-half (1.5×) the width W1T3 of the first tab 620, but in other embodiments, the second tab width W2T3 can be more than about one-and-one-half the first tab width W1T3 or less than about one-and-one-half the first tab width. The third cutout 626 has a width W3C3 that is about half (0.5×) of the width W1T3 of the first tab 620, but in other embodiments, the third cutout width W3C3 can be more than about half of the first tab width W1T3 or less than about half of the first tab width. In other embodiments, however, each cutout and tab may have different heights. In one exemplary embodiment, the first tab width W1T3 of the third shingle 606 is substantially equal to the first tab width W1T1 of the first shingle 602, though that is not required. Additionally, in one exemplary embodiment, the first cutout width W1C3 of the third shingle 606 is substantially equal to the first cutout width W1C1 of the first shingle 602, though that is not required.
In the exemplary embodiment, the height of each of the cutouts 618, 622, 626 and each of the tabs 620, 624 is equal to the tab portion height HT3. In other embodiments, however, each cutout and tab may have different heights. The third shingle 606 also includes a left edge 630 and a right edge 632. Left and right referring to the orientation of the third shingle as illustrated in
As with the roofing shingle system 200, the edge joints 810 in the first course 804 are covered by a tab from a shingle in the second course 806 and so on. Thus, during installation, as long as one shingle in the subsequent course is positioned such that a tab from that shingle overlays the edge joint in the previous course, preferably with a sidelap SL of about half the width of the narrowest tab, then the edge joints in the underlaying course will always be covered by a tab from the overlaying course, regardless of which shingles, or the order of the shingles, are laid. Further, the roofing shingle system 600 is designed for a sidelap SL to be about half of the first tab width W1T1; however, in other embodiments, the a sidelap SL may be more than or less than half of the first tab width W1T1.
Conventional three-tab shingles typically have a height of 12 inches and a width of 32 inches. When installed on a roof, about 6 inches of the shingle is exposed with the remaining height of the shingle being overlapped by the next course of shingles (i.e. 6 inches of headlap). As a result, of the 432 in2 of the upper face, 216 in2 are exposed and 216 in2 are covered (50% exposed). Conventional laminate shingles typically have a height of 13.25 inches and a width of 39.375 inches. When installed on a roof, about 5.625 inches of the shingle is exposed with the remaining height of the shingle being overlapped by the next course of shingles (i.e. 7.625 inches of headlap). As a result, of the 521.72 in2 of the upper face, 221.48 in2 are exposed (about 42.5% exposed).
As compared to conventional three-tab and laminate shingles, the shingles of the roofing shingle system 200 and the roofing shingle system 600 have a higher ratio of area that can potentially be exposed when installed as intended. Unlike conventional three-tab and laminate shingles which always have approximately the same exposed area, the different shingle patterns and the potential random ordering of shingles in the roofing shingle systems 200, 600, may result in a different amount of exposed area from shingle to shingle.
For example, the shingle 202 of
In the illustrated embodiment of
The overlay sheet 910 may be attached to the underlay sheet 912 by any suitable manner, such as for example, by a laminate adhesive, as is known in the art. In one exemplary embodiment, the laminate adhesive is applied to the underside of the overlay sheet 910 after the granule-coated sheet 906 is passed into contact with the rotary cutter 908. In other embodiments, however, the laminate adhesive is applied to the underside of the overlay sheet 910 prior to the rotary cutter 908.
The continuous laminated sheet 914 is subsequently passed into contact with one or more rotary pattern cutters 916 that cut continuous laminated sheet 914 through both the overlay sheet 910 and the underlay sheet 912 to section the continuous laminated sheet 914 into a first lane 918 of cut shingles and a second lane 920 of cut shingles that extend along the longitudinal axis A. Each of the first lane 918 and the second lane 920 alternate between the first shingle 902 and a second shingle 904 in the direction of the longitudinal axis A. In other embodiments, the continuous laminated sheet 914 may be cut to include more than two shingle patterns. For example, the continuous laminated sheet 914 may be cut similar to the sheet 600 of
The overlay sheet 910 and the underlay sheet 912 are adjacent each other on the granule-coated sheet 906 and the first lane 918 of cut shingles and a second lane 920 of cut shingles are interwoven. Thus, substantially no material from the granule-coated sheet 906 is scrap or waste. For the purpose of this disclosure, “substantially no scrap or waste material” refers to the interwoven shingle patterns and underlay sheet utilizing substantially all of the granule-coated sheet material as part of the formed shingles. Scrap or waste material, however, does not include material that would be removed, if any, by the rotary cutter as the cutter cuts along the perimeter of the shingle patterns, or excess material at the terminal end of a granule-coated sheet, or material discharged due to imperfections in the sheet or miscuttings, or similar circumstances resulting in the shingle not be deemed suitable for use.
The first shingle 902 and the second shingle 904 have a substantially similar shingle pattern to the first shingle 202 and the second shingle 204 of the shingle system 200, thus the description of the shingle pattern of the first shingle 202 and the second shingle 204 apply equally to the first shingle 902 and the second shingle 904 of
The overlay sheet 910 is disposed on and adhered to the underlay sheet 912 thereby defining both a two-layer portion 940 of the first shingle 902 and a single-layer portion 942 of the laminated shingle. The area of the overlay sheet 910 that overlaps the underlay sheet 912 in the head portion 924 is the common bond area 944. The height HC4 of the common bond area 944 may be vary in different embodiments of the shingle.
In an exemplary embodiment, the shingle system 900, the first shingle 902 has a width W4 of about 39.375 inches, a height H4 of about 13.25 inches, a head portion height HH4 of about 7.625 inches, a tab portion height HT4 of about 5.625 inches, width of about 7.875 inches for each of the cutouts 928, 932, 936 and tabs 930, 934, and a common bond area height HC4 of about 1.0 inch. The overlay sheet 918 has a height HOL4 of about 20.125 inches and the underlay sheet 920 has a height HUL4 of about 7.625 inches.
The above description of specific embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. For example, the general inventive concepts are not typically limited to asphalt based roofing material. Thus, for example, use of the inventive concepts to various roofing materials, such as for example roofing shingles and commercial roofing that is non-asphalt based, are within the spirit and scope of the general inventive concepts. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the generally inventive concepts, as described and claimed herein, and equivalents thereof.
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/097,775, filed on Dec. 30, 2014, the disclosure of which is incorporated herein by reference in their entireties.
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