CA2087278A1 - Roofing shingle preform and methods of manufacturing and using the same - Google Patents
Roofing shingle preform and methods of manufacturing and using the sameInfo
- Publication number
- CA2087278A1 CA2087278A1 CA 2087278 CA2087278A CA2087278A1 CA 2087278 A1 CA2087278 A1 CA 2087278A1 CA 2087278 CA2087278 CA 2087278 CA 2087278 A CA2087278 A CA 2087278A CA 2087278 A1 CA2087278 A1 CA 2087278A1
- Authority
- CA
- Canada
- Prior art keywords
- preform
- styrene
- recited
- modified bitumen
- shingle
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Laminated Bodies (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
Abstract
ROOFING SHINGLE PREFORM AND METHODS
OF MANUFACTURING AND USING THE SAME
ABSTRACT OF THE DISCLOSURE
A roofing shingle preform which includes a strip of bitumen membrane having a plurality of spaced tabs formed of a bitumen membrane attached thereto.
Preferably, the bitumen membrane is a modified bitumen membrane whyich includes a core of polyester having a layer of SBS or SEBS modified bitumen thereover. In manufacture, the preform is preferably formed into a roll and, in fabricating a roof from the preform, the roll is unwound in succeeding courses to form the roof.
OF MANUFACTURING AND USING THE SAME
ABSTRACT OF THE DISCLOSURE
A roofing shingle preform which includes a strip of bitumen membrane having a plurality of spaced tabs formed of a bitumen membrane attached thereto.
Preferably, the bitumen membrane is a modified bitumen membrane whyich includes a core of polyester having a layer of SBS or SEBS modified bitumen thereover. In manufacture, the preform is preferably formed into a roll and, in fabricating a roof from the preform, the roll is unwound in succeeding courses to form the roof.
Description
c~ 27 ~
ROOFING SHINGLE PREFORM AND METHODS
OF MA~IUFA~TURING ~D US ING TE~E SAME
The invention relate~ to roofing shingles and, more particularly, to a roofing ~hingle preform.
In the past, roofing shingles have been manufactured utilizing a number of different proces~es and a number of dif~erent materials. For example, roofing shingles have been made of single sheet~ of material, as well as laminate~. Laminates, however, are preferred becau3e they are believed to enhance the appearance of the finished shingled roof by pre~enting to the viewer~s eye a thicker edge ~or the shingle.
One conventional laminate shingle, as disclo3ed in U.S. Patent No. 4,869,942, is made of an asphalt-impregnated fiberglas~ material. The hingle has a broad central area and a narrow strip adhered along one edge of the central area. The combination ~hingle has tabs between cutout areas along the edge which has the double layer. A third layer is adhered to the tabs ~o form a layer underlying and bridging the gaps which separate the tabs.
Regardless of the composition of the shingle and the method of manufacture, all prior art shingles have one common characteristic: they are cut into discrete units which are then individually applied to the roof to ~orm the finished roof.
It i9 an object of the present invention to provide a new and improved roofing ~hingle preform and methods of manufacturing and using the same, which will SPEC\6863 ~ .
`"~.,~ ' , '. ' ; " ' i ,, 72~
enable a shingled roof to be formed in si tU wi.thout the necessity of handling and installing individual shingles.
The foregoing and other objects are achieved in accordance with the pre~ent invention by a shingle preform which compri~es a strip formed of a bitumen membrane having a plurality of spaced tabs of the same bitumen membrane adhered thereto.
Preferably, the composite material compri~es a substrate having a layer of modified bitumen ~hereover.
Preferably, the preform i9 ~abricated by adhering tab~ of the compo~ite material to a strip of the composite material and then coiling the strip into a roll.
In accordance with another aspect of the invention, in order to ~abricate a shingled roof, the '~
strip having the tabs adhered thereto is unwound from the roll and laid on the roof. Therea~ter, succeeding strips having tabs thereon are unwound from a roll and laid in overlapping fashion over each other, with the tab~ of each succeeding sheet intermediate the tabs of the immediately preceeding sheet ~o as to provide the shingle ef f ect.
The objects, advantages and features of the present invention will be better understood from the following detailed description, when considered in connection with the appended drawings, wherein:
SPEC\~t63 Fig. 1 illu~tra~es a roofing ~hingle preform in accordance with certain principles of the invention;
Fig. 2 i~ a croaa-sectional view taken along the lines 2-2 of F~g. 1;
Fig. 3 is a cross-~ectional view taken along the lines 3-3 of Fig. 1;
Fig. 4 is a plan view ~howing an alterna~ive embodiment of the novel roofing shingle preform;
Fig. 5 illustrates diagrammatically the proce~s of manufacturing the novel preform of Fig. 1 and forming the same into a roll; and Fig. 6 illustrate~ installa~ion of the novel ~hingle of Fig. 1 to a roof.
Referring now to the drawings and, in par~ic-ular, to Fig. 1, there i~ shown a roofing shingle preform 10 which includes a strip 11 and a plurality of tabs 12 attached to the strip 11 in ~paced fashion. The strip 10 is preferably formed of a modified bitumen membrane.
More specifically, referring to Fig. 2, the strip 11 includes a core 13 formed of fiberglass or polyester and an o~erlying layer 14 of either styrene-butadiene-styrene (SBS) modified bitumen or styrene-ethylene-butadiene-styrene (SEBS) modified bitumen, and the tabs 12 are each composed of a layer 16 identical in composition to the core 13 and a layer 17 identical in composition to the layer 14 (see Fig. 3).
In a typical roofing ~hingle preform 10, the width Ws of the strip and the width WT f the tab are each eight inches, the length LT Of the tab~ may be 8, 10 SPEC~6863 ~.~
.-~ : '. ':, : '. ' ~ . : .
727~
or 12 inches and the distance DT between the tabs may be 5-7 inches.
Although the tabs 12 are shown as having parallel sides, tapered tabs 12, a~ shown in Fig. 4, may be used to enhance the aesthe~ics of a roof shingled with the preform 1~.
Advantageously, a3 shown in Fig. 5, the preform 10 is fabricated in a continuous process, in which the strip 11 is advanced through a tab attachment station ~8 wherein the tab~ are attached to the strip 11 in spaced relationship. While any suitable method of attachment may be employed, preferably the top surface of the strip 11 is coated with an asphalt adhesive prior tO
application of the tab~ thereto. It iB not nece~sary that the entire surface area to which the t~bs are going to be attached be coated. Only an area Wc extending from an upper edge 21 toward~ a bottom edge 19 (upper and bottom referring to the relative po~itioning to these edges when a strip of the preform shingle is laid on a roof 22 (Fig. 6)), need be coated with the adhesive.
After exiting the ~tation lB, the strip is wound into a roll 23. The length of the strip 11 in each roll i~ determined by the weight of the roll 23 that may be easily handled by a roofer during installation.
TypicalIy, the strip 11 may be 30-32 feet long and the roll 23 may weigh 25-50 pounds.
Turning now to Fig. 6, there is shown a typical roof installation employing the roofing shingle preform 10. As is conventional, the roof deck 24 is first primed with an a~phalt primer and allowed to dry.
Thereafter, insulation panel~ (not shown) and a base sheet are attached to the underlying roof deck 24, using mechanical fa~teners.
SPEC~6863 :. , : ~ , . . : - . : ' . : ' ' :
" ' ' ' '' :
~' -' ' .: ' . -- :: ~.' ' '`,,~ ' '~87~78 Alternatively, the insulation panels and base sheet may be attached using a hot asphalt process. Therea~ter, starting at the low point of the roof deck 24, the preform is unwound from the roll 23 and applied to the roof using mechanical fastener~. Each succeeding strip is overlapped with the preceding strip, to provide a predetermined headlap. In shingle-type roofs, headlap is usually defined as the distance a hingle in any course overlaps a shingle in the cecond course below it.
Typically, headlap with the preform 10 is 3 inches. In addition to overlapping the immediately preceding preform lOa, each ~ucceeding preform tsuch as the preform lOb) is also offset from the preceding preform, so that the tabs 12b of the preform lOb are positioned intermediate the tabs 12a of the preform lOa.
As should be appreciated from the ~oregoing description, since the preform 10 i5 unwound from a ro,l, it enables the shingling to take place much more rapidly than would be the case if individual shingles were to be employed. Additionally, the thinness of the preform 10, as compared to conventional shingles, and the resulting lower weight, result in a lower weight roof, while providing the same protection from the elements and waterproofing.
Although the core 13 of the strip 11 and the core 14 of the tabs 12 may be formed of either fiberglass or polyester, when the preform 10 is to be formed into a roll 23, polye~ter is preferred because fibergla~s is too stiff.
Additionally, while other modi~ier resins may be employed, such as actactic polypropylene tAPP), SBS
and SEBS resins are preferred because each, when modified with such resins, is amenable to being attached using asphalt adhesives, wherea~ such i~ not true of APP resins S?EC\6863 .
- : ' ' ~
- 6 - 2~727~
and asphalt adhesives are the preferred material for attaching ~he tabs 12 to a strip 10.
As will be appreciated, the pre~ent invention has been de~cribed in relation to a particular illustrative embodiment thereof. Many other variations and processes will become appare~t to those skilled in the art. It i8 preferred, therefore, that the present invention be limited, not by the specific disclosure herein, but only by the appended claima.
SPEC\6863 . " `" :
, - ".
!
` ` ' ' ' " ` ' ' ' ` ' ' ~ ' `~ `
..
ROOFING SHINGLE PREFORM AND METHODS
OF MA~IUFA~TURING ~D US ING TE~E SAME
The invention relate~ to roofing shingles and, more particularly, to a roofing ~hingle preform.
In the past, roofing shingles have been manufactured utilizing a number of different proces~es and a number of dif~erent materials. For example, roofing shingles have been made of single sheet~ of material, as well as laminate~. Laminates, however, are preferred becau3e they are believed to enhance the appearance of the finished shingled roof by pre~enting to the viewer~s eye a thicker edge ~or the shingle.
One conventional laminate shingle, as disclo3ed in U.S. Patent No. 4,869,942, is made of an asphalt-impregnated fiberglas~ material. The hingle has a broad central area and a narrow strip adhered along one edge of the central area. The combination ~hingle has tabs between cutout areas along the edge which has the double layer. A third layer is adhered to the tabs ~o form a layer underlying and bridging the gaps which separate the tabs.
Regardless of the composition of the shingle and the method of manufacture, all prior art shingles have one common characteristic: they are cut into discrete units which are then individually applied to the roof to ~orm the finished roof.
It i9 an object of the present invention to provide a new and improved roofing ~hingle preform and methods of manufacturing and using the same, which will SPEC\6863 ~ .
`"~.,~ ' , '. ' ; " ' i ,, 72~
enable a shingled roof to be formed in si tU wi.thout the necessity of handling and installing individual shingles.
The foregoing and other objects are achieved in accordance with the pre~ent invention by a shingle preform which compri~es a strip formed of a bitumen membrane having a plurality of spaced tabs of the same bitumen membrane adhered thereto.
Preferably, the composite material compri~es a substrate having a layer of modified bitumen ~hereover.
Preferably, the preform i9 ~abricated by adhering tab~ of the compo~ite material to a strip of the composite material and then coiling the strip into a roll.
In accordance with another aspect of the invention, in order to ~abricate a shingled roof, the '~
strip having the tabs adhered thereto is unwound from the roll and laid on the roof. Therea~ter, succeeding strips having tabs thereon are unwound from a roll and laid in overlapping fashion over each other, with the tab~ of each succeeding sheet intermediate the tabs of the immediately preceeding sheet ~o as to provide the shingle ef f ect.
The objects, advantages and features of the present invention will be better understood from the following detailed description, when considered in connection with the appended drawings, wherein:
SPEC\~t63 Fig. 1 illu~tra~es a roofing ~hingle preform in accordance with certain principles of the invention;
Fig. 2 i~ a croaa-sectional view taken along the lines 2-2 of F~g. 1;
Fig. 3 is a cross-~ectional view taken along the lines 3-3 of Fig. 1;
Fig. 4 is a plan view ~howing an alterna~ive embodiment of the novel roofing shingle preform;
Fig. 5 illustrates diagrammatically the proce~s of manufacturing the novel preform of Fig. 1 and forming the same into a roll; and Fig. 6 illustrate~ installa~ion of the novel ~hingle of Fig. 1 to a roof.
Referring now to the drawings and, in par~ic-ular, to Fig. 1, there i~ shown a roofing shingle preform 10 which includes a strip 11 and a plurality of tabs 12 attached to the strip 11 in ~paced fashion. The strip 10 is preferably formed of a modified bitumen membrane.
More specifically, referring to Fig. 2, the strip 11 includes a core 13 formed of fiberglass or polyester and an o~erlying layer 14 of either styrene-butadiene-styrene (SBS) modified bitumen or styrene-ethylene-butadiene-styrene (SEBS) modified bitumen, and the tabs 12 are each composed of a layer 16 identical in composition to the core 13 and a layer 17 identical in composition to the layer 14 (see Fig. 3).
In a typical roofing ~hingle preform 10, the width Ws of the strip and the width WT f the tab are each eight inches, the length LT Of the tab~ may be 8, 10 SPEC~6863 ~.~
.-~ : '. ':, : '. ' ~ . : .
727~
or 12 inches and the distance DT between the tabs may be 5-7 inches.
Although the tabs 12 are shown as having parallel sides, tapered tabs 12, a~ shown in Fig. 4, may be used to enhance the aesthe~ics of a roof shingled with the preform 1~.
Advantageously, a3 shown in Fig. 5, the preform 10 is fabricated in a continuous process, in which the strip 11 is advanced through a tab attachment station ~8 wherein the tab~ are attached to the strip 11 in spaced relationship. While any suitable method of attachment may be employed, preferably the top surface of the strip 11 is coated with an asphalt adhesive prior tO
application of the tab~ thereto. It iB not nece~sary that the entire surface area to which the t~bs are going to be attached be coated. Only an area Wc extending from an upper edge 21 toward~ a bottom edge 19 (upper and bottom referring to the relative po~itioning to these edges when a strip of the preform shingle is laid on a roof 22 (Fig. 6)), need be coated with the adhesive.
After exiting the ~tation lB, the strip is wound into a roll 23. The length of the strip 11 in each roll i~ determined by the weight of the roll 23 that may be easily handled by a roofer during installation.
TypicalIy, the strip 11 may be 30-32 feet long and the roll 23 may weigh 25-50 pounds.
Turning now to Fig. 6, there is shown a typical roof installation employing the roofing shingle preform 10. As is conventional, the roof deck 24 is first primed with an a~phalt primer and allowed to dry.
Thereafter, insulation panel~ (not shown) and a base sheet are attached to the underlying roof deck 24, using mechanical fa~teners.
SPEC~6863 :. , : ~ , . . : - . : ' . : ' ' :
" ' ' ' '' :
~' -' ' .: ' . -- :: ~.' ' '`,,~ ' '~87~78 Alternatively, the insulation panels and base sheet may be attached using a hot asphalt process. Therea~ter, starting at the low point of the roof deck 24, the preform is unwound from the roll 23 and applied to the roof using mechanical fastener~. Each succeeding strip is overlapped with the preceding strip, to provide a predetermined headlap. In shingle-type roofs, headlap is usually defined as the distance a hingle in any course overlaps a shingle in the cecond course below it.
Typically, headlap with the preform 10 is 3 inches. In addition to overlapping the immediately preceding preform lOa, each ~ucceeding preform tsuch as the preform lOb) is also offset from the preceding preform, so that the tabs 12b of the preform lOb are positioned intermediate the tabs 12a of the preform lOa.
As should be appreciated from the ~oregoing description, since the preform 10 i5 unwound from a ro,l, it enables the shingling to take place much more rapidly than would be the case if individual shingles were to be employed. Additionally, the thinness of the preform 10, as compared to conventional shingles, and the resulting lower weight, result in a lower weight roof, while providing the same protection from the elements and waterproofing.
Although the core 13 of the strip 11 and the core 14 of the tabs 12 may be formed of either fiberglass or polyester, when the preform 10 is to be formed into a roll 23, polye~ter is preferred because fibergla~s is too stiff.
Additionally, while other modi~ier resins may be employed, such as actactic polypropylene tAPP), SBS
and SEBS resins are preferred because each, when modified with such resins, is amenable to being attached using asphalt adhesives, wherea~ such i~ not true of APP resins S?EC\6863 .
- : ' ' ~
- 6 - 2~727~
and asphalt adhesives are the preferred material for attaching ~he tabs 12 to a strip 10.
As will be appreciated, the pre~ent invention has been de~cribed in relation to a particular illustrative embodiment thereof. Many other variations and processes will become appare~t to those skilled in the art. It i8 preferred, therefore, that the present invention be limited, not by the specific disclosure herein, but only by the appended claima.
SPEC\6863 . " `" :
, - ".
!
` ` ' ' ' " ` ' ' ' ` ' ' ~ ' `~ `
..
Claims (22)
1. A roofing shingle preform comprising a strip of bitumen membrane having a plurality of spaced tabs formed of a bitumen membrane attached thereto.
2. A roofing shingle preform, as recited in claim 1, wherein the strip comprises a flat core having a top surface and a bottom surface and a modified bitumen layer on only the top surface.
3. A roofing shingle preform, as recited in claim 2, wherein the bitumen layer is a modified bitumen layer selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
4. A roofing shingle preform, as recited in claim 3, wherein the core is made of polyester.
5. A roofing shingle preform, as recited in claim 2, wherein the tabs are each formed of a roofing membrane comprising a flat core having a top surface and a bottom surface and a modified bitumen layer on only the top surface thereof.
6. A roofing shingle preform, as recited in claim 5, wherein the bitumen layer is a modified bitumen layer selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
7. A roofing shingle preform, as recited in claim 6, wherein the core of each tab is made of polyester.
8. A roofing shingle preform, as recited in claim 7, wherein the core of the strip is made of polyester.
9. A roofing shingle preform, as recited in claim 8, further including crushed aggregate in the modified bitumen layer of the strip and crushed aggregate in the modified bitumen layer of the tabs.
10. A roofing shingle preform, as recited in claim 9, wherein the tabs are 3-6 inches wide and the distance between the tabs is 5-7 inches.
11. A method of manufacturing a roofing shingle preform, comprising:
forming a strip comprised of a modified bitumen membrane;
attaching to the strip, in spaced relation-ship, a plurality of tabs formed of a modified bitumen membrane; and winding the strip, after attachment of the tabs thereto, into a roll.
forming a strip comprised of a modified bitumen membrane;
attaching to the strip, in spaced relation-ship, a plurality of tabs formed of a modified bitumen membrane; and winding the strip, after attachment of the tabs thereto, into a roll.
12. A method of manufacturing a roofing shingle preform, as recited in claim 11, wherein the strip comprises a flat core having a top surface and a bottom surface and a bitumen layer on only the top surface.
13. A method of manufacturing a roofing shingle preform, as recited in claim 12, wherein the bitumen layer is a modified bitumen layer being selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
14. A method of manufacturing a roofing shingle preform, as recited in claim 11, wherein the tabs are each formed of a roofing membrane comprising a flat core having a top surface and a bottom surface and a bitumen layer on only the top surface thereof.
15. A method of manufacturing a roofing shingle preform, as recited in claim 14, wherein the bitumen layer is a modified bitumen layer selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
16. A method of manufacturing a roofing shingle preform, as recited in claim 15, wherein the core of the tab and the core of the strip are each formed of polyester.
17. A method of manufacturing a shingle roof, comprising:
unwinding a roofing shingle preform from a roll of the same, the preform including a strip of roofing material having spaced tabs attached thereto;
attaching a first course of the preform to a roof; and attaching succeeding courses of the preform to the roof such that each succeeding course overlaps the immediately-preceding course with the tabs of each succeeding course intermediate the tabs of the immediately-preceding course.
unwinding a roofing shingle preform from a roll of the same, the preform including a strip of roofing material having spaced tabs attached thereto;
attaching a first course of the preform to a roof; and attaching succeeding courses of the preform to the roof such that each succeeding course overlaps the immediately-preceding course with the tabs of each succeeding course intermediate the tabs of the immediately-preceding course.
18. A method of fabricating a shingle roof, as recited in claim 17, wherein the strip comprises a flat core having a top surface and a bottom surface and a bitumen layer on only the top surface.
19. A method of fabricating a shingle roof, as recited in claim 17, wherein the bitumen layer is a modified bitumen layer selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
20. A method of fabricating a shingle roof, as recited in claim 17, wherein the tabs are each formed of a roofing membrane comprising a flat core having a top surface and a bottom surface and a modified bitumen layer on only the top surface thereof.
21. A method of fabricating a shingle roof, as recited in claim 17, wherein the birumen layer is a modified bitumen layer selected from the group consisting of styrene-butadiene-styrene modified bitumen and styrene-ethylene-butadiene-styrene modified bitumen.
22. A method of fabricating a shingle roof, as recited in claim 21, wherein the core of the tab and the core of the strip are each formed of polyester.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US82206092A | 1992-01-14 | 1992-01-14 | |
| US07/822,060 | 1992-01-14 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2087278A1 true CA2087278A1 (en) | 1993-07-15 |
Family
ID=25235012
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2087278 Abandoned CA2087278A1 (en) | 1992-01-14 | 1993-01-14 | Roofing shingle preform and methods of manufacturing and using the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2087278A1 (en) |
-
1993
- 1993-01-14 CA CA 2087278 patent/CA2087278A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued | ||
| FZDE | Discontinued |
Effective date: 19960714 |