Abstract: A method of making a laminated shingle is provided. The method includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, adhering a reinforcement member to a portion of the asphalt-coated sheet, covering the asphalt-coated sheet, and optionally covering the reinforcement member, with granules to make a granule-covered sheet, dividing the granule-covered sheet into an overlay sheet and an underlay sheet, wherein the overlay sheet has a tab portion normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, and wherein the reinforcement member is adhered to the lower zone of the headlap portion and laminating the overlay sheet and the underlay sheet to make the laminated shingle.

Abstract: This invention, in embodiments, relates to a roofing material comprising (a) a coated or covered substrate and (b) a single sealant applied to a surface of the coated or covered substrate, with the single sealant being free of asphalt. The single sealant exhibits a minimum activation temperature (° C.) (tan ?>1) from ?10° C. to 0° C. The single sealant is configured to adhere the roofing material to at least one of (i) an underlying roofing material, (ii) an overlying roofing material, and (iii) a roofing deck substrate.

Abstract: An article includes a first layer including a front surface and a back surface and a second layer including a front surface and a back surface. A portion of the second layer overlaps the first layer. A portion of the second layer is fastened to the first layer. The back surface of the first layer contacts the front surface of the second layer. A plurality of indentations along a major dimension of the roofing shingle. The plurality of indentations are configured to partially press the second layer into the first layer such that the second layer is partially indented into the first layer. The plurality of indentations are at least one of barrel-shaped, flattened teardrop shaped, rounded taper teardrop shaped, or combinations thereof.

Abstract: A hail resistant roofing system and method includes a roofing substrate such as a shingle or tile or membrane having an array of exposed upwardly projecting features. The features may rise to sharp points and may have side surfaces that are angled relative to the plane of the roofing substrate. The features are spaced and arranged so that a large hail stone capable of damaging the roofing substrate will always impact one or more of the exposed features. This can break up the hail stone into smaller benign pieces or can redirect the energy and direction of the hail stone so that the impact is absorbed without damage to the roofing substrate.

Abstract: A laminated composition shingle includes a first sheet having a first mineral granule surface and a first rectangular shape without tab cut-outs laminated with a second sheet having a second mineral granule surface. The second sheet has tab cut-outs along only one longer edge of the second sheet. The laminated composition shingle has a shingle width and an exposure width perpendicular to the long edges and a first width that is twice the exposure width. The shingle width is the first width plus 2 inches (51 mm). The tab cut-outs have a tab width in the direction of the shingle width less than the exposure width minus ? of an inch (3 mm).

Abstract: A roofing shingle has a shingle body with at least a top layer having a buttlap portion with a butt edge and a headlap portion. An exposure zone extends from the butt edge toward the headlap portion and is configured to be exposed to the environment when the roofing shingle is installed on a roof. A shadow formation may be located in the exposure zone of the top layer. The shadow formation and the exposure zone differ from each other in at least one aspect, such as color. The top layer may be substantially rectangular and have no tabs formed along the butt edge. A thickness of the exposure zone and a thickness of the shadow formation may be substantially identical. The shadow formation may be a simulated cut out, slit or slot.

Abstract: A roofing system including shingles with different shingle patterns. The roofing system may include 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.

Abstract: A radiant barrier has a layer of a flexible polymer, such as TPO, and a layer of metallic aluminum bonded thereto. A reinforcement layer, such as a fiberglass scrim, and a layer of adhesive, such as EVA, may be used to strengthen the barrier and prevent de-lamination. LDPE may be incorporated into the TPO to increase strength. The barrier may also be a moisture barrier. The layers may be laminated by a heated roll set and the aluminum applied by vapor deposition.

Abstract: A roofing shingle is provided comprising a reduced-with headlap portion including headlap projections, a buttlap portion including buttlap projections, a lateral leading edge, and a lateral trailing edge, wherein the headlap projection nearest the lateral leading edge has an increased breadth. A roofing system is also provided comprising a multiplicity of courses of shingles of the invention, wherein a lateral trailing edge of a shingle in a single course overlaps (side-laps) an adjacent previously installed shingle, and wherein a shingle in a subsequent course provides a generally uniform overlap region over the headlap portions of a first and second adjacent shingle in the first course and an expanded overlap region over the second adjacent shingle, wherein the expanded overlap region is due to the increased breadth of the headlap projection nearest the lateral leading edge of the second adjacent shingle in the first course.

Abstract: A method of making a laminated shingle is provided. The method includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, adhering a reinforcement member to a portion of the asphalt-coated sheet, covering the asphalt-coated sheet, and optionally covering the reinforcement member, with granules to make a granule-covered sheet, dividing the granule-covered sheet into an overlay sheet and an underlay sheet, wherein the overlay sheet has a tab portion normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, and wherein the reinforcement member is adhered to the lower zone of the headlap portion and laminating the overlay sheet and the underlay sheet to make the laminated shingle.

Abstract: A multiple-layer laminated shingle and a method of making the shingle are provided, in which at least one adhesive of high temperature resistance is applied for securing the shingle layers together, to reduce reliance on a roofer having to fasten (via nails, staples or other fatteners) through a narrow headlap zone of a posterior shingle layer in order to secure the posterior shingle layer to a roof; such that a vertically wide portion of the headlap area of the anterior shingle layer is presented to the roofer as of nailing zone.

Abstract: A roofing shingle includes a shingle body having a buttlap portion with a butt edge and a headlap portion with a head edge. The shingle body also has a first side edge, a second side edge, and an exposure zone extending from the butt edge toward the headlap portion that is configured to be exposed to the environment when the shingle is installed on a roof. A water impermeable sheet is attached to the shingle body. The sheet has a width, length, first end and second end. The width extends from approximately the head edge to approximately the butt edge of the shingle body. The length extends from the first end to the second end. At least a portion of the length extends beyond the first side edge of the shingle body by at least about 2 inches. The sheet is formed from a different material than the shingle body.

Abstract: A roofing shingle has a shingle body with a butt edge, a headlap portion, a head edge, and first and second side edges. An exposure zone has a width that extends from the butt edge toward the headlap portion and is configured to be exposed to the environment when the shingle is installed on a roof. A water impermeable sheet is attached to the shingle body. The sheet has a width with upper and lower edges. The width extends from between about the butt and head edges to beyond the head edge of the shingle body. The width of the shingle body is such that a first distance between the head edge of the shingle body and the upper edge of the water impermeable sheet is equal to or greater than the width of the exposure zone. The sheet is formed from a different material than the shingle body.

Abstract: A multiple-layer laminated shingle and a method of making the shingle are provided, in which at least one adhesive of high temperature resistance is applied for securing the shingle layers together, to reduce reliance on a roofer having to fasten (via nails, staples or other fatteners) through a narrow headlap zone of a posterior shingle layer in order to secure the posterior shingle layer to a roof; such that a vertically wide portion of the headlap area of the anterior shingle layer is presented to the roofer as of nailing zone.

Abstract: A roofing shingle includes a substrate having a headlap portion and a tab portion. Reinforcement material is secured to the headlap portion, wherein the reinforcement material is formed from woven material.

Abstract: A hip, ridge or rake shingle is provided, in which a pair of substantially rigid panel portions are connected by a hinge portion, and wherein the shingle is pre-assembled, but can conform to a variety of different angles to accommodate different angular relationships between surfaces of a hip, ridge or rake of a roof. The substantially rigid panel portions are connected by a hinge and may or may not have a reinforcement member, and all of the panels, hinges and reinforcement members are of synthetic thermoplastic polymeric construction and are welded together by ultrasonic or vibratory welding techniques.

Abstract: A multiple-layer laminated shingle and a method of making the shingle are provided, in which at least one thermal set adhesive of high temperature resistance is applied for securing the shingle layers together, to reduce reliance on a roofer having to fasten (via nails, staples or other fasteners) through a narrow headlap zone of a posterior shingle layer in order to secure the posterior shingle layer to a roof; such that a vertically wide portion of the headlap area of the anterior shingle layer is presented to the roofer as a nailing zone.

Abstract: A multi-layered shingle includes an underlay sheet having a longitudinally extending axis and a leading edge. The underlay sheet further defines a first layer and a second layer. The second layer is connected to the first layer along a first longitudinally extending fold line and folded against the first layer. An overlay sheet is bonded to the underlay sheet, and the first and second layers of the underlay sheet define multiple layers of a multi-layered shingle.

Abstract: A laminated roofing shingle is provided, having an anterior shingle layer and a posterior shingle layer. Openings exist in tab portions of the anterior shingle layer, allowing for visible front surface portions of the posterior shingle layer to be visible through the openings. Such visible portions can be of varying vertical contrast from at least some of the top edges of the openings to at least some of the bottom edges of the posterior shingle layer that are exposed through the openings, and are generally of consistent horizontal contrast between right and left edges of the openings. Front surface portions of the posterior shingle layer that are exposed through one or more openings have a different contrast that is in interrupting contrast to at least a portion of any of the varying or consistent contrast that are visible through the openings between tabs of the anterior shingle layer.

Abstract: A roofing shingle is provided. The roofing shingles includes an overlay sheet including a headlap portion and a tab portion and an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet. A reinforcement material is secured to the headlap portion of the overlay sheet. The reinforcement material is configured to improve nail pull-through. The reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a distance of about 0.12 inches or less.

Abstract: A roofing shingle is provided. The roofing shingles includes an overlay sheet including a headlap portion and a tab portion and an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet. A reinforcement material is secured to the headlap portion of the overlay sheet. The reinforcement material is configured to improve nail pull-through. The reinforcement material extends beyond the overlapping regions of the headlap portion and the underlay sheet a distance of about 0.12 inches or less.

Abstract: A laminated roofing shingle is provided, having an anterior shingle layer and a posterior shingle layer. Openings exist in tab portions of the anterior shingle layer, allowing for visible front surface portions of the posterior shingle layer to be visible through the openings. Such visible portions can be of varying vertical contrast from at least some of the top edges of the openings to at least some of the bottom edges of the posterior shingle layer that are exposed through the openings, and are generally of consistent horizontal contrast between right and left edges of the openings. Front surface portions of the posterior shingle layer that are exposed through one or more openings have a different contrast that is in interrupting contrast to at least a portion of any of the varying or consistent contrast that are visible through the openings between tabs of the anterior shingle layer.

Abstract: A method of covering a roof deck includes laying a course of starter shingles in a side-by-side relationship at an eave edge of a roof deck. A starter shingle of the course of starter shingles is a laminated starter shingle comprising an underlay sheet laminated below an overlay sheet. A plurality of successive generally horizontal courses of covering shingles are laid above the course of starter shingles. The covering shingles in each of the courses of covering shingles are laid in a side-by-side relationship and horizontally offset from the covering shingles in adjacent courses. Each covering shingle of the courses of covering shingles includes a headlap portion and a butt portion. The butt portion includes a plurality of tabs separated by cutouts. The starter shingles include an exposed portion extending between the tabs of the covering shingles.

Abstract: A roofing shingle is disclosed comprising a headlap portion with a non-straight longitudinal edge and a buttlap portion with a plurality of tabs with a non-straight longitudinal edge and spaced apart by openings, wherein the non-straight longitudinal edges do not shadow each other laterally across the shingle. A roofing system is disclosed wherein at least a portion of the headlap portion of such shingle from a subsequently installed course overlaps at least a portion of the headlap portion of a shingle from a previously installed course. The maximum headlap overlap dimension is beneath the subsequently installed shingle laterally proximate the openings in the buttlap portion of the subsequently installed shingle. A method for making the shingle is disclosed comprising cutting a sheet of roofing material longitudinally along non-straight lines wherein at least a portion of each formed shingle has a width of about twelve inches.

Abstract: In one embodiment, a shingle includes a first layer having at least one full tab and at least one full cut-out. A second layer is positioned under the first layer. The full tab width to first layer length ratio is greater than 8.5/36. The full cut-out width to first layer length ratio is greater than 8.5/36. A method that includes applying such shingles to a roof.

Abstract: The present invention provides a roof shingle comprising a shingle with at least one layer having a head lap and a butt, the head lap including at least one alignment notch and the butt including at least one corner that corresponds to the alignment notch. Also, the present invention provides a roofing shingle comprising at least one layer formed from a cutting cylinder having a circumference that is a fraction of said roofing shingle length. The present invention also provides a method for manufacturing the inventive shingles and a method for installing the inventive shingles upon a roofing area.

Abstract: A shingle, an array of shingles, and a process for producing the shingles, either of the field shingle type, or of the hip, ridge or rake type, wherein the shingles have a shortened headlap portion for purposes of reducing the amount of material necessary to make the shingle, wherein each of the shingles has a fastening zone for receiving fasteners therethrough, which fastening zone is an overlay of granule covered adhesive, and is in the headlap portion, and wherein a contact zone layer of adhesive is provided on the rear of the tab portion of the shingle, for contact against the overlay of granule covered adhesive when a next-overlying shingle is arranged in an array above a next-underlying shingle.

Abstract: A laminated roofing shingle is provided, having an anterior shingle layer and a posterior shingle layer. Openings exist in tab portions of the anterior shingle layer, allowing for visible front surface portions of the posterior shingle layer to be visible through the openings. Such visible portions can be of varying vertical contrast from at least some of the top edges of the openings to at least some of the bottom edges of the posterior shingle layer that are exposed through the openings, and are generally of consistent horizontal contrast between right and left edges of the openings. Front surface portions of the posterior shingle layer that are exposed through one or more openings have a different contrast that is in interrupting contrast to at least a portion of any of the varying or consistent contrast that are visible through the openings between tabs of the anterior shingle layer.

Abstract: The present invention provides a roof shingle comprising a shingle with at least one layer having a head lap and a butt, the head lap including at least one alignment notch and the butt including at least one corner that corresponds to the alignment notch. Also, the present invention provides a roofing shingle comprising at least one layer formed from a cutting cylinder having a circumference that is a fraction of said roofing shingle length. The present invention also provides a method for manufacturing the inventive shingles and a method for installing the inventive shingles upon a roofing area.

Abstract: An assembly, and method for constructing the assembly, to aid in the proper installation of shingles by providing panels of shingles and assembly guides that when followed, result in the installation of shingles that meet keyway width requirements, keyway alignment requirements, provide an aesthetically pleasing distribution of the shingles, and provides adequate ventilation.

Abstract: A multi-layered roofing shingle is described. The layers of the shingle are connected via a mechanical fastener. A method for manufacturing a multi-layered shingle is also described. The method includes aligning the layers of the shingle, and connecting the layers via at least one mechanical fastener. Further described is a multi-layered shingle having layers that are mechanically fastened by deforming one of the layers into one of the other layers.

Abstract: An assembly, and method for constructing the assembly, to aid in the proper installation of shingles by providing panels of shingles and assembly guides that when followed, result in the installation of shingles that meet keyway width requirements, keyway alignment requirements, provide an aesthetically pleasing distribution of the shingles, and provides adequate ventilation.

Abstract: A roofing shingle (74) includes an asphalt-coated sheet (18) having a tab portion (78) normally exposed on a roof and a headlap portion (76) normally covered-up on a roof. The headlap portion has a lower zone (76A) that extends longitudinally between a first end (74A) and a second end (74B) of the roofing shingle adjacent the tab portion, and an upper zone (76B) adjacent the lower zone. At least a portion of the asphalt-coated sheet has granules adhered thereto. A reinforcement member (19) is adhered to the lower zone of the headlap portion.

Abstract: A roofing shingle is provided. The roofing shingle includes an overlay sheet including a headlap portion and a tab portion and an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet. Said underlay sheet has a substantially uniform thickness. A reinforcement member is secured to the headlap portion. The reinforcement member is formed from a material selected from the group consisting of paper, film, scrim, woven, and non-woven material. The reinforcement member and the portion of the headlap portion to which the reinforcement member is secured to improve nail pull-through. At least some of the reinforcement member does not overlap the overlapping regions of the headlap portion and the underlay sheet. Said reinforcement member provides said overlay sheet with a non-uniform thickness.

Abstract: A laminated shingle and a method of making it is provided in which the rear surface of the shingle is provided with an attached reinforcement layer through which fasteners may be applied when the shingle is applied to a roof.

Abstract: A bundle of laminated shingles is provided. The bundle includes a plurality of shingles having an overlay laminated with an underlay. The overlay has a tab portion with cutouts normally exposed on a roof and a headlap portion. The headlap portion has a lower zone adjacent the tab portion and an upper zone adjacent said lower zone. The lower zone has substantially no granules adhered thereto. The bundle defines a central area that substantially encompasses the lower zones of the stacked shingles. The shingles are stacked such that every other of the shingles is inverted and turned 180 degrees relative to an adjacent shingle. The shingles are double-layered, wherein the lack of granules in the lower zones of the stacked shingles results in the central area of the bundle having a height substantially identical to a height of a remainder of the bundle outside of the central area.

Abstract: A composite shingle having unitary construction is presented that includes a body shell, a plurality of longitudinal ribs, and a plurality of rib stiffeners. The present composite shingle may also include transverse ribs, a depressed nailing zone, nailing zone ribs, and/or at least one alignment aid. The plurality of rib stiffeners may include a material saving profile. Further, the dimensions of the composite shingle more closely resemble true slate and shake shingles and at least a portion of the outside face of composite shingle may be textured to resemble slate or wood shake shingles. A plurality of assembled composite shingles of the present invention is also claimed as part of this invention. Finally, a method of applying multiple courses of shingles on a roof including the composite shingle of the present invention is presented.

Abstract: A multi-layered roofing shingle is described. The layers of the shingle are connected via a mechanical fastener. A method for manufacturing a multi-layered shingle is also described. The method includes aligning the layers of the shingle, and connecting the layers via at least one mechanical fastener. Further described is a multi-layered shingle having layers that are mechanically fastened by deforming one of the layers into one of the other layers.

Abstract: A roofing shingle with a laying line that facilitates the alignment of an overlying course of shingles with respect an underlying course of shingles is provided. The laying line is located on a front surface of the shingle and has a width such that the laying line is exposed when an edge of another shingle is placed in contacting proximity with the laying line. The shingle may also have a scale and one or more nibs that protrude from the sides of the shingle that assist in aligning the shingles in the second course with the shingles in the underlying course. The shingle may also include nailing zones located on the front surface of the shingles provide a location for fastening the shingles to the roof. A method of laying the shingles of the present invention on a roof is also provided.

Abstract: A starter block and a shingle are utilized to form courses that may be positioned in overlapping fashion on a roof to form a roofing covering system. The particular design of the starter block and shingle result in a roofing product that provides increased durability over previous designs. The starter block may be formed with top and bottom surfaces, opposite side surfaces with tapering heights, and a front surface having a greater height than a back surface of the starter block. When the starter block is coupled to a roof deck, a semi-rigid shingle having a generally planar bottom surface may be placed upon the starter block so that a portion of the shingle extends off of the starter block over the back surface thereof and onto the roof deck to facilitate contact between the shingle and the roof deck at a location more proximal to the starter block back surface than if the same back surface had the same height as the front surface.

Abstract: A multi-layered roofing shingle is described. The layers of the shingle are connected via a mechanical fastener. A method for manufacturing a multi-layered shingle is also described. The method includes aligning the layers of the shingle, and connecting the layers via at least one mechanical fastener. Further described is a multi-layered shingle having layers that are mechanically fastened by deforming one of the layers into one of the other layers.

Abstract: A roofing shingle with a laying line that facilitates the alignment of an overlying course of shingles with respect an underlying course of shingles is provided. The laying line is located on a front surface of the shingle and has a width such that the laying line is exposed when an edge of another shingle is placed in contacting proximity with the laying line. The shingle may also have a scale and one or more nibs that protrude from the sides of the shingle that assist in aligning the shingles in the second course with the shingles in the underlying course. The shingle may also include nailing zones located on the front surface of the shingles provide a location for fastening the shingles to the roof. A method of laying the shingles of the present invention on a roof is also provided.

Abstract: An improved roofing material having an upper and lower surface in which a thin layer comprising re-melted polypropylene or other suitable plastic is adhered to at least a portion of its lower surface.

Abstract: A roofing shingle includes an asphalt-coated sheet having a tab portion normally exposed on a roof and a headlap portion normally covered-up on a roof. The headlap portion has a lower zone that extends longitudinally between a first end and a second end of the roofing shingle adjacent the tab portion, and an upper zone adjacent the lower zone. At least a portion of the asphalt-coated sheet has granules adhered thereto. A reinforcement member is adhered to the lower zone of the headlap portion.

Abstract: A roofing shingle comprising a mat having regions of various thicknesses. A layer of asphalt-based material coats the mat and a layer of granules is deposited on the asphalt-coated mat. The variations in the thickness of the regions of the mat give the shingle differences in thickness corresponding to the thickness variations in the regions of the mat, thereby giving the shingle an appearance of depth.

Abstract: A simulated shingle structure comprising a wood board with a base and an upper edge, the base having a thickness greater than the upper edge, and a plurality of vertical cuts extending partially through a front face of a board. In one embodiment, a portion of the base is removed such that the shingles will appear to have differing lengths.

Abstract: The present invention provides a roof shingle comprising a shingle with at least one layer having a head lap and a butt, the head lap including at least one alignment notch and the butt including at least one corner that corresponds to the alignment notch. Also, the present invention provides a roofing shingle comprising at least one layer formed from a cutting cylinder having a circumference that is a fraction of said roofing shingle length. The present invention also provides a method for manufacturing the inventive shingles and a method for installing the inventive shingles upon a roofing area.

Abstract: A shingle and a method of making it is provided in which the rear surface of the shingle is provided with an attached reinforcement layer through which fasteners may be applied when the shingle is applied to a roof.

Abstract: A hip, ridge or rake shingle is provided, having a high profile, by using various shingle layers to form a built-up wedge-shaped headlap portion, comprised of a plurality of layers of different dimensions in the headlap portion of the shingle, and the process for manufacturing the same from a single sheet of shingle material is provided.

Abstract: A shingle layer of shingle is provided having an increased thickness adhesive coating on at least a portion of its rear surface, with granules embedded therein, with the granules being of a size range that is larger than the fine particles normally applied to the rear surface of a shingle layer.