ROOFING SHINGLES AND METHODS OF MAKING AND AFFIXING SAME
A roofing shingle (20) comprises a web (22) having a shingle major dimension (24) and a shingle minor dimension (26). The web (22) in turn comprises a headlap portion (30) and plural tabs (32). The headlap portion (30) extends along a web first edge (34) which is parallel to the shingle major dimension. The plural tabs (32) are formed along a web second edge (36) which is parallel to the web first edge. Adjacent ones of the plural tabs (32) are separated by a cut out (40). The cut out (40) extends in the shingle minor dimension (26). As formed, each of the plural tabs (30) has a greater extent along the shingle minor dimension (26) than along the shingle major dimension (24).
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I. Technical Field
This invention pertains to roofing shingles and methods of affixing roofing shingles to a sloped roof.
II. Related Art and other Considerations
Roofing shingles are some of the most prevalent forms of roofing materials. Roofing shingles are particularly popular for residential buildings. While shingle appearance and design must be appealing, shingle manufacture and installment should be efficient.
Shingle production typically involves feeding a substrate into a production line. In the production line, hot asphalt is applied to the substrate. Granules are deposited and embedded into the substrate. The granules which are embedded into what will be, upon installation, an exposed portion of the substrate, are often called “finish” granules, and may be of a particular color or combination of colors. Typically less colorful or less esthetically appealing granules are embedded into an un-exposed or “butt” portion of the substrate, also called the headlap portion. The granule laden substrate is then cut to a package length, e.g. into a package unit, along a major dimension of the shingle. For many general purpose shingles the package unit has a number of tabs on its lower or exposed surface, e.g. three tabs; which are separated by slots which extend in a minor dimension (e.g., height) of the shingle.
Certain large format shingles measure 18 inches along their height (in the shingle minor dimension). See, for example, U.S. Pat. No. 5,501,056; U.S. Pat. No. 5,375,491; U.S. Pat. No. 5,421,134; and U.S. Pat. No. 5,287,669. In the shingle minor dimension, the large format shingles of the listed patents have a ratio of exposed area (e.g., tab height) to headlap portion of 8:10. In other words, the tab of the large format shingle extends 8 inches along the shingle height, while the headlap or butt portion of the large format shingle extends 10 inches along the shingle height. Each large format shingle is sufficiently long in the shingle major dimension so that, whether the shingle is a four tab or three tab shingle, each tab has a greater length than height. An advantage in using large format shingles is that fewer nails are required to secure the shingle to a roof.
BRIEF SUMMARYOne aspect of the technology pertains to a roofing shingle. In one example embodiment, the roofing shingle comprises a web having a shingle major dimension and a shingle minor dimension. The web in turn comprises a headlap portion and plural tabs. The headlap portion extends along a web first edge. The web first edge is parallel to the shingle major dimension. The plural tabs are formed along a web second edge. The web second edge is parallel to the web first edge. Adjacent ones of the plural tabs are separated by a cut out. The cut out extends in the shingle minor dimension. As formed, each of the plural tabs has a greater extent along the shingle minor dimension than along the shingle major dimension.
In an example implementation, for each of the plural tabs, a ratio of a tab extent along the shingle minor dimension to a tab extent along the shingle major dimension is in a ratio of 136:113. Each of the plural tabs measures substantially 8 and ½ inches along the shingle minor dimension and substantially 7 and 1/16 inches along the shingle major dimension. Each tab preferably has a corner defined by the cut out, the corner being angularly truncated. The web preferably measures substantially 22 and 11/16 inches in the shingle major dimension and substantially 18 and ½ inches in the shingle minor dimension. A ratio of a tab extent along the shingle minor axis to measurement of the web along the shingle minor axis is preferably in a ratio of 17:20.
In an example implementation, the plural tabs comprise material of contrasting coloration relative to the headlap portion.
In another example implementation, the headlap portion comprises a sealant on an upper surface thereof. The headlap portion preferably comprises two linear stripes of sealant, with both a first stripe of sealant and a second stripe of sealant being by formed by discontinuous segments of sealant material. The segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered relative to one another along the shingle major dimension. Preferably the segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered to form offset channels along the shingle minor direction.
In another example embodiment, the roofing shingle comprises a web having a shingle major dimension and a shingle minor dimension. The web comprises a headlap portion and plural tabs. The headlap portion extends along a web first edge, the web first edge being parallel to the shingle major dimension. The plural tabs are formed along a web second edge, the web second edge being parallel to the web first edge. Adjacent ones of the plural tabs are separated by a cut out. The headlap portion comprises two linear stripes of sealant, with both a first stripe of sealant and a second stripe of sealant being by formed by discontinuous segments of sealant material. Segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered relative to one another along the shingle major dimension to form offset channels along the shingle minor direction.
In an example implementation, the cut out extends in the shingle minor dimension, with each of the plural tabs having a greater extent along the shingle minor dimension than along the shingle major dimension.
Yet another aspect of the technology involves a method of applying roofing shingles to a roof. Shingles for use with the method each comprise a web having a shingle major dimension and a shingle minor dimension. The web in turns comprises a headlap portion and plural tabs. The headlap portion extends along a web first edge, the web first edge being parallel to the shingle major dimension. The plural tabs are formed along a web second edge. The web second edge is parallel to the web first edge. Adjacent ones of the plural tabs are separated by a cut out. The cut out extends in the shingle minor dimension. Each of the plural tabs having a greater extent along the shingle minor dimension than along the shingle major dimension.
The example method comprises acts of (1) affixing a first shingle to the roof; (2) positioning a second shingle over a portion of the first shingle in such a manner that a degree of exposure of the cutout of the first shingle provides a tab of the first shingle with a desired visibly perceived geometrical configuration. The degree of exposure depends on a situation characteristic of the roof.
In one example mode of the method, the situational characteristic of the roof is angle of roof inclination relative to a ground plane. In another example mode of the method, the situational characteristic of the roof is roof height relative to a ground plane. In yet another example mode, the desired visually perceived geometrical configuration of the tab is a square.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular architectures, interfaces, techniques, etc. in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. That is, those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. In some instances, detailed descriptions of well-known devices, invention with unnecessary detail. All statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
The web 22 comprises headlap portion 30 and plural tabs 32, such as the three tabs illustrated as tabs 32A, 32B, and 32C in
Adjacent ones of the plural tabs 32 are separated by a slot or cut out 40. For example, tab 32A and 32B are separated by cutout 40AB, and tab 32B and 32C are separated by cutout 40BC. Each cutout 40 has its major dimension in the shingle minor dimension 26, and thus extends in the shingle minor dimension 26. Each cutout 40 extends 8 and ½ inches in the shingle minor dimension 26, and (except at its intersection with web second edge 36) extends ½ inch in the shingle major dimension 24. Along its web third edge 37, tab 32A has a notch 42A which measures 8 and ½ inches along shingle minor dimension 26 and ¼ inch along shingle major dimension 24. Similarly, along its web fourth edge 38, tab 32C has notch 42C which measures 8 and ½ inches along shingle minor dimension 26 and ¼ inch along shingle major dimension 24.
As mentioned above, roofing shingle 20 has a measurement of 18 and ½ inches along shingle minor dimension 26. In other words, roofing shingle 20 has a shingle height of 18 and ½ inches. The headlap portion 30 has a measurement of 10 inches along the shingle minor dimension 26. Each of the plural tabs thus measures substantially 8 and ½ inches along the shingle minor dimension 26 and substantially 7 and 1/16 inches along the shingle major dimension 24. The tabs 32 thus have a length of 7 and 1/16 inch from tab center to tab center.
Thus, in contrast to conventional large format shingles, each of the plural tabs 32 has a greater extent along the shingle minor dimension 26 than along the shingle major dimension 24. For each of the plural tabs 32 of the
Thus, in its flat or plan view, the roofing shingle 20 has a taller appearance than conventional large format shingles. However, when installed on a sloping roof and thus viewed at a rendered angle (the angle depending on roof slope angle) from ground level, the shingle has a more square appearance. For example, the less steep the roof angle, the more square the roofing shingle 20 appears.
Along web second edge 36, each tab 32 preferably has an angularly truncated corner 46 where web second edge 36 intersects with cutout 40. The angled truncation for each corner 46 extends one inch along shingle major dimension 24 and one inch along shingle minor dimension 26. Thus, in the illustrated example embodiment, the angle of the truncated corner 46 is 45 degrees.
In an example implementation, the plural tabs 32 comprise material of contrasting coloration relative to headlap portion 30, which may be uncolored or dark.
For each of the embodiments of
As also shown in
One aspect of the technology involves a method of applying roofing shingles to a roof to obtain a pattern or arrangement such as that illustrated in
In the particular illustration of
Thus, a formed, each of the plural tabs 32 has a greater extent along the shingle minor dimension 26 than along the shingle major dimension 24. However, the degree of overlap or overlaying of successive shingles can be controlled so that each shingle tab has a desired appearance as viewed from a vantage point such as ground level. In the desired appearance, the shingle tab may have a same extent along the shingle minor dimension 26 as along the shingle major dimension 24 (e.g., an essentially square appearance), or (if desired) even a smaller extent along the shingle minor dimension 26 as along the shingle major dimension 24 (e.g., an essentially rectangular appearance).
In an example implementation in which a three tab shingle is utilized, the following measurements were noted:
-
- the overall shingle width is 22 and 1/16 inch
- the overall shingle height is 18.50 inch
- the nominal individual tab size is 8.5 inch by 7.0625 inch
- the headlap area height is 10.0″ inch (from top of cut out)
- the exposed, continuous, horizontal shadowline is approximately ¾ inch below the tabs, on the face of the shingle
- ½ inch cutout rain grooves expose the headlap as the contrasting background;
- each three tab shingle covers 192.8 square inch of exposed roof area when installed at 8.5 inch exposure with a full width shingle (8.5 inch by 22.6875 inch)
- 4 nails are used per shingle, meaning 300 nails per square
- the ratio of each tab's height to width is 120.4
- the ratio of tab height to total shingle height is 45.95
- ratio of headlap height to total shingle height is 54.1
- 75 shingles installed per 100.44 square feet of coverage
- dual, stitched seal down lines of adhesive with stitched gaps offset from line to line
- lower sealant line is placed such to coincide with the upper corner of the notched lower tab corners
- upper seal line is placed one inch oc. above the lower sealant line
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
Claims
1. A roofing shingle comprising a web having a shingle major dimension and a shingle minor dimension, the web comprising:
- a headlap portion extending along a web first edge, the web first edge being parallel to the shingle major dimension;
- plural tabs formed along a web second edge, the web second edge being parallel to the web first edge, adjacent ones of the plural tabs being separated by a cut out, the cut out extending in the shingle minor dimension, each of the plural tabs having a greater extent along the shingle minor dimension than along the shingle major dimension.
2. The roofing shingle of claim 1, wherein for each of the plural tabs, a ratio of a tab extent along the shingle minor dimension to a tab extent along the shingle major dimension is in a ratio of 136:113.
3. The roofing shingle of claim 1, wherein each of the plural tabs measures substantially 8 and ½ inches along the shingle minor dimension and substantially 7 and 1/16 inches along the shingle major dimension.
4. The roofing shingle of claim 3, wherein each tab has a corner defined by the cut out, and wherein the corner is angularly truncated.
5. The roofing shingle of claim 3, wherein the web measures substantially 22 and 11/16 inches in the shingle major dimension and substantially 18 and ½ inches in the shingle minor dimension.
6. The roofing shingle of claim 1, wherein a ratio of a tab extent along the shingle minor axis to measurement of the web along the shingle minor axis is in a ratio of 17:20.
7. The roofing shingle of claim 1, wherein the plural tabs comprise material of contrasting coloration relative to the headlap portion.
8. The roofing shingle of claim 1, wherein the headlap portion comprises a sealant on an upper surface thereof.
9. The roofing shingle of claim 8, wherein the headlap portion comprises two linear stripes of sealant, both a first stripe of sealant and a second stripe of sealant being by formed by discontinuous segments of sealant material, and wherein the segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered relative to one another along the shingle major dimension.
10. The roofing shingle of claim 9, wherein the segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered to form offset channels along the shingle minor direction.
11. A roofing shingle comprising a web having a shingle major dimension and a shingle minor dimension, the web comprising:
- a headlap portion extending along a web first edge, the web first edge being parallel to the shingle major dimension;
- plural tabs formed along a web second edge, the web second edge being parallel to the web first edge, adjacent ones of the plural tabs being separated by a cut out;
- wherein the headlap portion comprises two linear stripes of sealant, both a first stripe of sealant and a second stripe of sealant being by formed by discontinuous segments of sealant material, and wherein the segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered relative to one another along the shingle major dimension.
12. The roofing shingle of claim 11, wherein the segments of the first stripe of sealant and the segments of the second stripe of sealant are staggered to form offset channels along the shingle minor direction.
13. The roofing shingle of claim 11, wherein the cut out extends in the shingle minor dimension, each of the plural tabs having a greater extent along the shingle minor dimension than along the shingle major dimension.
14. A method of applying roofing shingle to a roof, each shingle comprising a web having a shingle major dimension and a shingle minor dimension, the web comprising:
- a headlap portion extending along a web first edge, the web first edge being parallel to the shingle major dimension;
- plural tabs formed along a web second edge, the web second edge being parallel to the web first edge, adjacent ones of the plural tabs being separated by a cut out, the cut out extending in the shingle minor dimension, each of the plural tabs having a greater extent along the shingle minor dimension than along the shingle major dimension;
- wherein the method comprises:
- affixing a first shingle to the roof,
- positioning a second shingle over a portion of the first shingle in such a manner that a degree of exposure of the cutout of the first shingle provides a tab of the first shingle with a desired visibly perceived geometrical configuration, the degree of exposure depending on a situation characteristic of the roof.
15. The method of claim 14, wherein the situational characteristic of the roof is angle of roof inclination relative to a ground plane.
16. The method of claim 14, wherein the situational characteristic of the roof is roof height relative to a ground plane.
17. The method of claim 14, wherein the desired visibly perceived geometrical configuration of the tab is a square.
Type: Application
Filed: Nov 30, 2007
Publication Date: Jun 4, 2009
Applicant: Atlas Roofing Corporation (Meridian, MS)
Inventors: William E. TODD (Atlanta, GA), Robert MOORE (Marietta, TX), John LYTLE (Ardmore, OK), Kevin WILKIE (Arlington, TX)
Application Number: 11/948,062
International Classification: E04D 1/12 (20060101); E04D 1/00 (20060101);