Hip And Ridge Roofing Material

Abstract

A shingle blank is provided comprising a substrate coated with an asphalt coating and configured to include a prime region. The asphalt coating includes an upper section and a lower section, the upper section is positioned above the substrate and the lower section is positioned below the substrate. A web is applied to the lower section of the prime region. At least one perforation line is positioned in the shingle blank. The at least one perforation line is sufficient to facilitate separation of the shingle blank.

Description

TECHNICAL FIELD

This invention relates to asphalt-based roofing materials. More particularly, the invention pertains to hip and ridge roofing material having improved durability and impact resistance to withstand the destructive forces of storms.

BACKGROUND OF THE INVENTION

Asphalt-based roofing materials, such as roofing shingles, roll roofing, and commercial roofing, are installed on the roofs of buildings to provide protection from the elements. Typically, the roofing material is constructed of a substrate, such as a glass fiber mat or an organic felt, an asphalt coating on the substrate, and a surface layer of granules embedded in the asphalt coating.

The typical roofing material construction is suitable under most circumstances. However, sometimes a roofing material is subjected to environmental conditions that may damage the roofing material. For example, storms are responsible for billions of dollars in damage to roofing materials every year. During storms, hailstones may impact the roofing material, which may cause tears or punctures in the roofing material. The hailstone impacts may also cause an immediate loss of some granules from the impacted areas of the roofing material and a further loss of granules from those areas over time.

The loss of granules creates an unattractive appearance and leaves the asphalt coating in those areas unprotected from the degrading effects of the elements.

Roofing materials are applied to roofs having various surfaces formed by roofing planes. The various surfaces and roofing planes form intersections, such as hips and ridges. Hips are formed by the intersection of two sloping roof planes running from a ridge to the eaves. A ridge is the uppermost horizontal intersection of two sloping roof planes. It would be desirable to improve the roofing material used for hips and ridges to have an improved ability to withstand the destructive forces of storms.

SUMMARY OF THE INVENTION

According to this invention there is provided a shingle blank comprising a substrate coated with an asphalt coating and configured to include a prime region. The asphalt coating includes an upper section and a lower section, the upper section is positioned above the substrate, the lower section is positioned below the substrate. A web is applied to the lower section of the prime region. At least one perforation line is positioned in the shingle blank. The at least one perforation line is sufficient to facilitate separation of the shingle blank.

According to this invention there is also provided a method of manufacturing an asphalt-based roofing material comprising the steps of coating a substrate with an asphalt coating to form an asphalt coated sheet, the asphalt coated sheet includes an upper section and a lower section, applying a surface layer of granules to the upper section of the asphalt coated sheet, applying a web to the lower section of the asphalt coated sheet and forming at least one perforation line substantially across the asphalt coated sheet.

According to this invention there is also provided a method of installing an asphalt-based roofing material comprising the steps of providing an asphalt-based shingle blank having a substrate coated with an asphalt coating and configured to include an upper section and a lower section, a web is applied to the lower section, at least one perforation line is positioned substantially across the asphalt coated shingle blank, forming hip or ridge shingles by separating the shingle blank along the at least one perforation line and installing the hip and ridge shingles upon a hip or ridge.

According to this invention there is also provided a shingle blank comprising a substrate coated with an asphalt coating and configured to include a prime region. The asphalt coating includes an upper section and a lower section, the upper section is positioned above the substrate, the lower section is positioned below the substrate. A web is applied to the lower section of the prime region. At least one notch is positioned in the shingle blank. The at least one notch is sufficient to facilitate separation of the shingle blank.

According to this invention there is also provided a shingle blank comprising a substrate coated with an asphalt coating and configured to include a prime region. The asphalt coating includes an upper section and a lower section, the upper section is positioned above the substrate, the lower section is positioned below the substrate. A web is applied to the lower section of the prime region. At least one courtesy cut is positioned in the shingle blank. The at least one courtesy cut is sufficient to facilitate separation of the shingle blank.

Various advantages of this invention 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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building structure incorporating the hip and ridge roofing material according to the invention.

FIG. 2 is a perspective view of the installation of the ridge roofing material of FIG. 1.

FIG. 3 is a perspective view of a shingle blank used for making the hip and ridge roofing material of FIG. 2.

FIG. 4 is an enlarged cross-sectional view, taken along the line 4-4 of FIG. 3, of a portion of the hip and ridge roofing material of FIG. 3.

FIG. 5 is a perspective view of the shingle blank of FIG. 3 illustrating the formation of the individual hip and ridge shingles of FIG. 2.

FIG. 5A is an enlarged cross-sectional view, taken along the line 5A-5A of FIG. 5, of a portion of the shingle blank illustrating the perforation of the shingle blank including the web.

FIG. 5B is a second embodiment of the shingle blank of FIG. 5 illustrating a notched prime region.

FIG. 5C is a third embodiment of the shingle blank of FIG. 5 illustrating courtesy cuts.

FIG. 6 is a schematic view in elevation of apparatus for manufacturing an asphalt-based roofing material according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The description and drawings disclose a substantially storm-proof hip and ridge roofing material for a roofing system. With reference to FIG. 1, a building structure 10 is shown having a shingle-based roofing system 12. While the building structure 10 illustrated in FIG. 1 is a residential home, it should be understood that the building structure 10 can be any type of structure, such as a garage, church, arena or commercial building, having a shingle-based roofing system 12.

The building structure 10 has a plurality of roof planes 14a-14d. The term “roof plane” as used herein is defined to mean a plane defined by a flat portion of the roof formed by an area of roof deck. Each of the roof planes 14a-14d has a slope. The term “slope” as used herein is defined to mean the degree of incline of the roof plane. While the roof planes 14a-14d shown in FIG. 1 have their respective illustrated slopes, it should be understood that the roof planes 14a-14d can have any suitable slope. The intersection of the roof planes 14b and 14c form a hip 16. The term “hip” as used herein is defined to mean the inclined external angle formed by the intersection of two sloping roof planes. Similarly, the intersection of the roof planes 14b and 14d form a ridge 18. The term “ridge” as used herein is defined to mean the uppermost horizontal external angle formed by the intersection of two sloping roof planes.

The building structure 10 is covered by the roofing system 12 having a plurality of shingles 20. In the illustrated embodiment, the shingles 20 are a storm proof, asphalt-based roofing material of the type disclosed in U.S. Pat. No. 6,709,994 to Miller et al., which is incorporated by reference, in its entirety. As shown in FIG. 2, the shingles 20 are installed on the various roof decks in generally horizontal courses 22a-22g in which the shingles 20 overlap the shingles of a preceding course. While the shingles 20 shown in FIG. 2 are of a storm proof design, it should be understood that any suitable shingle can be used.

Hip and ridge roofing materials are installed to protect hips and ridges from the elements. As shown in FIG. 2, ridge roofing materials 24 are installed on the ridge 18 and over the shingles 20. In a similar fashion, hip roofing materials (not shown) are installed on a hip and over the shingles. The method of installing the hip and ridge roofing materials 24 will be discussed in more detail below.

Hip and ridge roofing materials are made from shingle blanks 26 as shown in FIG. 3. In the illustrated embodiment, the shingle blank 26 includes a headlap region 28 and a prime region 30. The headlap region 28 of the shingle blank 26 is the portion of the hip or ridge roofing material that is covered by successive overlapping hip or ridge roofing material when the hip or ridge roofing materials are installed. The prime region 30 of the shingle blank 26 is the portion of the hip or ridge roofing material that remains exposed when the hip or ridge roofing materials are installed. In other embodiments, the shingle blank can include only a prime region and no headlap region.

Referring again to FIG. 3, the shingle blank 26 may have any suitable dimensions. The shingle blank 26 may also be divided between the headlap region 28 and the prime region 30 in any suitable proportion. For example, a typical residential roofing shingle blank 26 has a length L of approximately 36 inches (91.5 cm) and a height H of approximately 12 inches (30.5 cm) high, with the height H dimension being divided between the headlap region 28 and the prime region 30. In one embodiment, the height of the headlap region 28 is approximately 2 inches (5.1 cm) greater than the height of the prime region 30. Alternatively, the height of the headlap region 28 can be more or less than 2 inches greater than the height of the prime region 30. In other embodiments, the height of the prime region can be the same as the height H of the shingle blank 26.

FIG. 4 illustrates one embodiment of the composition of the shingle blank 26 according to the invention. In this embodiment, the shingle blank 26 has the same composition and the same storm proof properties as the incorporated '994 patent to Miller et al. which is only summarized herein. In another embodiment, the shingle blank 26 can have other suitable compositions. As shown in FIG. 4, the roofing material includes a substrate 44 that is coated with an asphalt coating 46. The asphalt coating 46 includes an upper section 48 that is positioned above the substrate 44 when the roofing material is installed on a roof, and a lower section 50 that is positioned below the substrate 44. The upper section 48 includes an upper surface 52. In the illustrated embodiment, a protective coating 40 is adhered to the upper surface 52 of the upper section 48 of the asphalt coating 46. In other embodiments, the roofing material 46 can have compositions that do not include the protective coating 40. Referring again to FIG. 4, a layer of granules 42 is pressed into the protective coating 40. As shown in FIG. 4 and as described in the '994 patent to Miller et al., a portion of the granules 42 is completely enveloped by the protective coating 40 and another portion of the granules 42 protrudes from the protective coating 40. The protective coating 40 can be any material suitable for simultaneously forming a layer that is effective to improve the durability of the roofing material and effective to adhere the granules 40 to the asphalt coating 46, such as many types of the imoplastic, thermoset, or asphalt-based polymeric materials.

Optionally, a stabilizer can be added to the protective coating 40 to tailor the protective coating 40 to specialized conditions, such as extreme exposures of ultraviolet light, solar radiation, and/or temperature. The protective coating 40 can also contain other additives, such as algaecides, fungicides, or pigments.

Referring again to FIGS. 3 and 4, a web 56 is bonded to the lower section 50 of the asphalt coating 46. As described in the '994 patent to Miller et al., bonding of the web 56 to the lower section 50 of the asphalt coating 46 provides a resistance to a variety of impacts. The improved impact resistance substantially eliminates or reduces the occurrence of punctures or tears in the roofing material caused by impacts, and thereby maintains the integrity of the roofing material. The roofing material retains its ability to protect the building from the elements so that, for example, water leaks are avoided. There is no need to add a layer of impact-resistant material to the upper section 48 of the asphalt coating 46. The web 56 can be bonded to the asphalt coating 46 at any location in the lower section 50. The web 56 can be bonded to the asphalt coating 46 in any manner suitable to provide a bond such that the web 56 does not separate from the asphalt coating 46. One example of a strong bond between the web 56 and the asphalt coating 46 is achieved by fusing the web 56 and the asphalt coating 46. Specifically, a portion of the web 56 and the asphalt coating 46 are intermingled by melting, thereby fusing the web 56 and the asphalt coating 46. “Intermingled” includes any type of physical and/or chemical intermingling of the web and the asphalt coating, to provide a strong mechanical and/or chemical bond. Other examples of achieving a strong bond between the web 56 and the asphalt coating 46 are provided in the incorporated '994 patent to Miller et al. Optionally, to facilitate the fusing of the web 56 to the asphalt coating 46, various suitable multi-component webs can be used. The web 56 can be any type of web 56 suitable for use in the present invention. The material and structure of the web 56 are chosen so that the web 56 is effective to improve the impact resistance of the roofing material.

Referring now to the embodiment shown in FIG. 5, the shingle blank 26 includes a first perforation line 60 and a second perforation line 62. The perforation lines, 60 and 62, include perforations 64. The perforation lines, 60 and 62, are spaced apart substantially perpendicular to the length L of the shingle blank 26 and across the headlap region 28 and the prime region 30. The perforation lines, 60 and 62, are positioned such that subsequent separation of the shingle blank 26 along the perforation lines, 60 and 62, forms ridge roofing material 24. In the illustrated embodiment, the perforations 64 extend through the upper section 48 of the asphalt coating 46, the substrate 44, the lower section 50 of the asphalt coating 46 and the web 56. In other embodiments, the perforations 64 can extend through any suitable layers of the shingle blank 26. The perforations 64 can be arranged in any suitable pattern to form the perforation lines, 60 and 62. As one example of a perforation pattern, the perforations 64 can be about 0.25 inches long and spaced apart from edge to edge by about 0.25 inches. In another embodiment of a perforation pattern, the perforations 64 can be about 0.50 inches long and spaced apart from edge to edge about 0.50 inches. Alternatively, the perforations can be any suitable length and can be spaced apart edge to edge by any suitable length. The perforations 64 are configured such that an installer is able to separate the shingle blanks 26 into the ridge shingles 24 at the installation site. In the illustrated embodiment, the perforation lines, 60 and 62, extend the full height H of the shingle blank 26. Alternatively, the perforation lines, 60 and 62, can extend any length sufficient to enable an installer to separate the shingle blanks 26 into the ridge roofing materials 24 at an installation sight. While the embodiment shown in FIG. 5 illustrates two perforation lines, 60 and 62, it should be understood that more or less than two perforation lines can be used.

Referring now to FIG. 5A and as discussed above, the shingle blank 26 includes a web 56. The web 56 has a depth DW. In one embodiment, the depth DW of the web can be about 0.01 to about 0.07 inches, or about 0.02 to about 0.05, or about 0.03 to about 0.04. In the illustrated embodiment, the depth DW of the web 56 is approximately 0.03125 inches. Alternatively, the depth DW of the web 56 can be more or less than 0.03125 inches.

As shown in FIG. 5A, the perforation line 60 includes perforation 64. In the illustrated embodiment, the perforation 64 extends the full depth of the shingle blank 26. Alternatively, the perforation 64 can extend to less than the full depth of the shingle blank 26.

In another embodiment of the shingle blank 126 shown in FIG. 5B, a plurality of notches, 161a and 161b, are positioned in the prime region 130 of the shingle blank 126. In the illustrated embodiment, the notches, 161a and 161b, are configured to substantially align with the perforation lines, 160 and 162. As shown in the illustrated embodiment, the notches, 161a and 161b, extend substantially through the thickness of the shingle blank 126. In other embodiments, the notches, 161a and 161b, can extend through any suitable layers of the shingle blank 126. In the illustrated embodiment, the notches, 161a and 161b, extend substantially across the prime region 130 of the shingle blank 126. In other embodiments, the notches, 161a and 161b, can extend more or less across the prime region 130 of the shingle blanks 126. In other embodiments, the notches, 161a and 161b, can extend across the prime region 130 and into the headlap region. In yet other embodiments, the shingle blank 126 can include the notches, 161a and 161b, without having the corresponding perforation lines, 160 and 162. While the illustrated embodiment shows two notches, 161a and 161b, it should be understood that more than or less than two notches, 161a and 161b, can be used. Referring again to FIG. 5B, the notches, 161a and 161b, are configured to assist the installer in separating the shingle blanks 126. As will be explained below in more detail, the perforations lines, 160 and 162, and the optional notches, 161a and 161b, are provided in the shingle blank 126 during the manufacture of the shingle blank 126.

In another embodiment of the shingle blank 226 shown in FIG. 5C, a plurality of headlap courtesy cuts 263a are positioned in the headlap region 228 and a plurality of prime courtesy cuts 263b are positioned in the prime region 230 of the shingle blank 226. In the illustrated embodiment each of the headlap courtesy cuts 263a is configured to substantially align with a corresponding prime courtesy cut 263b. As shown in the illustrated embodiment, the headlap courtesy cuts 263a and the prime courtesy cuts 263b extend substantially through the thickness of the shingle blank 226. In other embodiments, the courtesy cuts, 263a and 263b, can extend through any suitable layers of the shingle blank 226. In the illustrated embodiment, the headlap courtesy cuts 263a extend across the headlap prime region 228 a distance DHC. In one embodiment, the distance DHC is approximately 1.0 inches. In other embodiments, the distance DHC can be more or less than 1.0 inches. Similarly, the prime courtesy cuts 263b extend across the prime region 230 a distance DPC. In one embodiment, the distance DPC is approximately 1.0 inches. In other embodiments, the distance DPC can be more or less than 1.0 inches. While the illustrated embodiment shows two headlap courtesy cuts 263a and two prime courtesy cuts 263b, it should be understood that more than or less than two headlap courtesy cuts 263a and more or less than two prime courtesy cuts 263b can be used. Referring again to FIG. 5C, the courtesy cuts, 263a and 263b, are configured to assist the installer in separating the shingle blanks 226. As will be explained below in more detail, the courtesy cuts, 263a and 263b, are provided in the shingle blank 226 during the manufacture of the shingle blank 226.

The process and apparatus to manufacture the shingle blank 26 is described in the '994 patent to Miller et al. and is only summarized herein. Referring now to FIG. 6, there is shown an apparatus 70 for manufacturing perforated shingle blanks according to the invention. The illustrated manufacturing process involves passing a continuous sheet 72 in a machine direction (indicated by the arrows) through a series of manufacturing operations. In one embodiment, the sheet 72 typically moves at a speed of at least about 200 feet/minute (61 meters/minute) or 300 feet/minute (91 meters/minute), and in another embodiment, typically at a speed within the range of between about 450 feet/minute (137 meters/minute) and about 800 feet/minute (244 meters/minute). Although the invention is shown and described in terms of a continuous process, it should be understood that the invention can also be practiced in a batch process using discreet lengths of materials instead of continuous sheets.

In a first step of the manufacturing process, the continuous sheet 72 of substrate is payed out from a roll 74. The substrate can be any type known for use in reinforcing asphalt-based roofing materials, such as a nonwoven web, scrim or felt of fibrous materials, such as glass fibers, mineral fibers, cellulose fibers, rag fibers, mixtures of mineral and synthetic fibers, or the like. Combinations of materials can also be used in the substrate. The sheet 72 of substrate is passed from the roll 74 through an accumulator 76. The accumulator 76 allows time for splicing one roll of substrate to another, during which time the substrate within the accumulator 76 is fed to the manufacturing process so that the splicing does not interrupt manufacturing.

Next, the sheet 72 is passed through a coater 78 where an asphalt coating 46 is applied to the sheet 72 to completely cover the sheet 72 with a tacky coating. The asphalt coating 46 can be applied in any suitable manner, such as for example, spraying or rolling the asphalt coating on to the sheet 72. Coating the sheet 72 with the asphalt coating 46 forms coated sheet 80.

The term “asphalt coating” means any type of bituminous material suitable for use on a roofing material such as asphalts, tars, pitches, or mixtures thereof. The asphalt can be either manufactured asphalt produced by refining petroleum or naturally occurring asphalt. The asphalt coating 46 can include various additives and/or modifiers, such as inorganic filters, mineral stabilizers, or organic materials, such as polymers, recycled streams, or ground tire rubber.

As further shown in FIG. 6, the asphalt-coated sheet 80 is passed beneath an optional applicator 82, where the optional protective coating 40 is applied to portions of the upper surface 52 of the upper section 48 of the asphalt coating 46. The optional protective coating 40 can be applied to the upper surface 52 of the upper section 48 of the asphalt coating 46 by any suitable method) such as for example by application as a film. The sheet 80 is then passed beneath a granule dispenser 84 for the application of granules 42 to the optional protective coating 40. While the embodiment shown in FIG. 6 illustrates a single granule dispenser 84, it should be appreciated than any number of granule dispensers 84 can be used. After deposit of the granules 42, the sheet 80 is turned around a slate drum 86 to press the granules 42 into the protecting coating 40 and the asphalt coating 46 and to temporarily invert the sheet 80.

Referring again to FIG. 6, the roofing material also includes the web 56. The web 56 is selected for the type of roofing material and is positioned and bonded in such a manner as to provide the roofing material with improved impact resistance to a variety of impacts. As shown in FIG. 6, the web 56 is payed out from a roll 96 onto the lower surface of the sheet 80 while the sheet 80 is inverted on the slate drum 86. As the sheet 80 turns around the slate drum 86, the asphalt coating 46 is still hot, soft and tacky, so that the web 56 adheres to the lower surface of the asphalt coating 46 and is pulled around the slate drum 86 along with the sheet 80. The web 56 is applied to the lower surface of the sheet 80 in the prime portions 30, but not in the headlap portions 28. Application of the web 56 beneath just the prime portion 30 of a roofing material provides improved impact resistance to the portion of the roofing material exposed to the elements on a roof, while minimizing the overall cost of the roofing material. While the embodiment shown in FIG. 6 illustrates one method of applying a web to the roofing material, it should be understood that other suitable bonding methods, such as for example heat sealing, ultrasonic welding, pressure sensitive or hot melt adhesive, electrostatic bonding, and physical intertwining by such means as needling or stitching, can be used. Bonding the web 56 to the sheet 80 forms webbed sheet 98.

In the illustrated embodiment, webbed sheet 98 is passed between backing roller 99a and press roller 99b. The rollers, 99a and 99b, are configured to compress the webbed sheet 98 sufficient to embed the granules 42 into the webbed sheet 98. Passing the webbed sheet 98 through the backing roller 99a and the press roller 99b forms embedded sheet 100.

Referring again to FIG. 6, after the embedded sheet 100 is formed by the backing roller 99a and the press roller 99b, the embedded sheet 100 is cooled by any suitable cooling apparatus 101, or allowed to cool at ambient temperature to form a cooled sheet 102.

The cooled sheet 102 is passed through applicators 104 and 105. The applicators, 104 and 105, are configured to apply a sealant to the surfaces of the cooled sheet 102. The applicators, 104 and 105, can be any suitable mechanism for applying the sealant to the cooled sheet 102. In the illustrated embodiment, the applicator 104 applies the sealant to the top surface of the cooled sheet 102 and the applicator 105 applies the sealant to the bottom surface of the cooled sheet 102. In other embodiments, the sealant can be applied to just the top or bottom surfaces of the cooled sheet 102. Application of the sealant to the cooled sheet 102 forms sealed sheet 107.

The sealed sheet 107 is passed through cutting roller 108a and anvil roller 108b. In the illustrated embodiment the rollers, 108a and 108b, are configured to perform several manufacturing operations. First, the cutting roller 108a and the anvil roller 108b are configured to form the perforation lines, 60 and 62, having the perforations 64. As discussed above, the perforations 64 can have any desired configuration and the perforation lines, 60 and 62, can be positioned anywhere along the length L of the shingle blank 26. The cutting roller 108a includes a plurality of perforating knives 109 spaced apart along a tangential line. The perforating knives 109 rotate with the rotation of the perforating roller and form the perforations 64 upon contact with the sealed sheet 107. Second, the cutting roller 108a and the anvil roller 108b can be configured to form the notches, 161a and 161b, formed in the prime region 130 of the shingle blank 126 as shown in FIG. 5B. Third, the cutting roller 108a and the anvil roller 108b can be configured to form the headlap courtesy cuts 263a formed in the headlap region 228 of the shingle blank 226 as shown in FIG. 5C and also configured to form the prime courtesy cuts 263b formed in the prime region 230 of the shingle blank 226 as also shown in FIG. 5C. Last, the cutting roller 108a and the anvil roller 108b can be configured to cut the sealed sheet 107 to form individual shingle blanks 26.

While FIG. 6 illustrates one example of an apparatus configured for forming the perforations 64, forming the notches 161a and 161b, forming the headlap courtesy cuts 263a, forming the prime courtesy cuts 263b and cutting the individual shingle blanks 26, it should be understood that other suitable mechanisms or combinations of mechanisms can be used.

The shingle blanks 26 are collected and packaged. While the embodiment shown in FIG. 6 illustrates the perforating and cutting processes as a single process, it is within the contemplation of this invention that the perforating and cutting processes can be completed at different times and by different apparatus.

Referring again to FIG. 5, the shingle blanks 26 arrive at the installation site having perforation lines 60 and 62. During installation, the roofing installer cuts or tears the shingle blank 26 along the perforation lines, 60 and 62 to form hip and ridge roofing materials 24. The perforations 64 allow for hip and ridge roofing materials 24 to be formed from the shingle blanks 26 as the perforations 64 allow the substrate 44 and the web 56 to be readily cut or torn. The formed hip and ridge roofing materials 24 have perforated edges 122. The configuration of the perforations 64 result in a perforated edge 122 which in some embodiments is somewhat ragged. As one example, if the individual perforations 64 have a relatively long length or if a larger quantity of perforations 64 are used, then the perforation edges 122 are somewhat smoother. Conversely, if the individual perforations 64 have a relatively short length or if a fewer number of perforations 64 are used, then the perforation edges 122 are somewhat more ragged. The hip and ridge roofing materials 24 are installed in overlapping sequence as shown in FIG. 2.

The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.

Claims

1. A shingle blank comprising:

a substrate coated with an asphalt coating and configured to include a prime region, the asphalt coating including an upper section and a lower section, the upper section being positioned above the substrate, the lower section being positioned below the substrate; and

a web applied to the lower section of the prime region;

wherein at least one perforation line is positioned in the shingle blank, the at least one perforation line being sufficient to facilitate separation of the shingle blank.

2. The shingle blank of claim 1 in which the blank has a length and wherein the at least one perforation line extends substantially across the shingle blank in a direction substantially perpendicular to the length of the shingle blank.

3. The shingle blank of claim 1 in which the at least one perforation line includes a plurality of perforations.

4. The shingle blank of claim 3 in which the perforations have a length of about 0.25 inches.

5. The shingle blank of claim 3 in which the perforations are spaced apart a distance of about 0.25 inches from edge to edge.

6. The shingle blank of claim 3 in which the perforations extend through the substrate, the upper and lower sections of the asphalt coating and the web.

7. The shingle blank of claim 1 in which the web has a depth of approximately 0.03125 inches.

8. A method of manufacturing an asphalt-based roofing material, comprising the steps of:

coating a substrate with an asphalt coating to form an asphalt coated sheet, the asphalt coated sheet including an upper section and a lower section;

applying a surface layer of granules to the upper section of the asphalt coated sheet;

applying a web to the lower section of the asphalt coated sheet; and

forming at least one perforation line substantially across the asphalt coated sheet.

9. The method of claim 8 in which the shingle blank has a length and wherein the at least one perforation line extends substantially across the shingle blank in a direction substantially perpendicular to the length of the shingle blank.

10. The method of claim 9 in which the at least one perforation line includes a plurality of perforations.

11. The method of claim 10 in which the perforations have a length of about 0.25 inches.

12. The method of claim 10 in which the perforations are spaced apart a distance of about 0.25 inches from edge to edge.

13. The method of claim 10 in which the perforations extend through the substrate, the upper and lower sections of the asphalt coated sheet and the web.

14. A method of installing an asphalt-based roofing material, comprising the steps of:

providing an asphalt-based shingle blank having a substrate coated with an asphalt coating and configured to include an upper section and a lower section, a web is applied to the lower section, wherein at least one perforation line is positioned substantially across the asphalt-based shingle blank;

forming hip or ridge shingles by separating the shingle blank along the at least one perforation line; and

installing the hip and ridge shingles upon a hip or ridge.

15. A shingle blank comprising:

a substrate coated with an asphalt coating and configured to include a prime region, the asphalt coating including an upper section and a lower section, the upper section being positioned above the substrate, the lower section being positioned below the substrate; and

a web applied to the lower section of the prime region;

wherein at least one notch is positioned in the shingle blank, the at least one notch being sufficient to facilitate separation of the shingle blank.

16. The shingle blank of claim 15 in which the shingle blank has a length and wherein the at least one notch extends substantially across the prime region of the shingle blank in a direction substantially perpendicular to the length of the shingle blank.

17. The shingle blank of claim 15 in which the at least one notch extends through the substrate, the upper and lower sections of the asphalt coating and the web.

18. A shingle blank comprising:

a substrate coated with an asphalt coating and configured to include a prime region, the asphalt coating including an upper section and a lower section, the upper section being positioned above the substrate, the lower section being positioned below the substrate; and

a web applied to the lower section of the prime region;

wherein at least one courtesy cut is positioned in the shingle blank, the at least one courtesy cut being sufficient to facilitate separation of the shingle blank.

19. The shingle blank of claim 18 in which the shingle blank has at least one courtesy cut positioned in the prime regions and at least one courtesy cut positioned in a headlap region.

20. The shingle blank of claim 19 in which the at least one courtesy cut positioned in the prime region substantially aligns with the at least one courtesy cut positioned in the headlap region