CA2144362A1 - Roofing shingle preform and methods of manufacturing and using the same - Google Patents

Roofing shingle preform and methods of manufacturing and using the same

Info

Publication number
CA2144362A1
CA2144362A1 CA 2144362 CA2144362A CA2144362A1 CA 2144362 A1 CA2144362 A1 CA 2144362A1 CA 2144362 CA2144362 CA 2144362 CA 2144362 A CA2144362 A CA 2144362A CA 2144362 A1 CA2144362 A1 CA 2144362A1
Authority
CA
Canada
Prior art keywords
preform
strip
recited
styrene
tabs
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
Application number
CA 2144362
Other languages
French (fr)
Inventor
John P. Hageman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2144362A1 publication Critical patent/CA2144362A1/en
Abandoned legal-status Critical Current

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  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

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 which 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. During installation, the roll is unwound in succeeding courses to form the roof. Preferably, only the top portion of each tab is secured to the underlying strip so that during installation the tab may be folded up and the underlying strip nailed to a previously laid course.

Description

-ROOFING SHING!~ P~FFORM AND METHODS
OF MANUFACTURING AND USING TH~ SAME

The invention relates to roofing shingles and, more particularly, to a roofing shingle preform.
In the past, roofing shingles have been manufactured utilizing a number of different processes and a number of different materials. For example, roofing shingles have been made of single sheets of material, as well as laminates. Laminates, however, are preferred because they are believed to enhance the appearance of the finished shingled roof by presenting to the viewer's eye a thicker edge for the shingle.
One conventional laminate shingle, as disclosed in U.S. Patent No. 4,869,942, is made of an asphalt-impregnated fiberglass material. The shingle has a broad central area and a narrow strip adhered along one edqe of the central area. The combination shingle has tabs between cutout areas along the edge which has the double layer. A third layer is adhered to the tabs to 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 form the finished roof.
It is an object of the present invention to provide a new and improved roofing shingle preform and " ~ "

214~362 _ - 2 -methods of manufacturing and using the same, which will enable a shingled roof to be formed in situ without the necessity of handling and installing individual shingles.
The foregoing and other objects are achieved in accordance with the present invention by a shingle preform which comprises a strip formed of a bitumen membrane having a plurality of spaced tabs of the same bitumen membrane adhered thereto. Preferably, the bitumen membrane is the roofing membrane described in copending application Serial No. 07/822,059 entitled "Bitumen Roofing Membrane" filed on even date herewith, in the name of John P. Hageman and assigned to the same assignee, as the present invention, which application is incorporated by reference herein.
Preferably, the composite material comprises a substrate having a layer of modified bitumen thereover, the preform is fabricated by adhering tabs of the composite material and the strip is then coiled into a roll.
In accordance with an aspect of the present invention, only a top portion of each tab is adhered to the underlying strip. This then enables the bottom portion of each tab to be lifted from-its underlying strip and the strip secured by mechanical fasteners, such as nails, to an underlying layer, thereby providing instantaneous sealing of the strip to the underlying layer. After nailing, the bottom portions of the tabs are then lowered back onto the strip, thereby covering the nails so that no nails show. The aesthetics of the roof, therefore, are not impaired. In contrast, in conventional shingling, nails are not employed to seal the shingles but, instead, the heat of the sun, over time, is relied upon to seal the shingles to underlying shingles. Unfortunately, such sealing takes some time and may not, even after sealing, be completely effective "

21~362 to prevent leaking and other damage to the roof. In addition, before sealing, the shingles and the underlying roof are subject to damage from the weather.
In accordance with another aspect of the invention, in order to fabricate a shingled roof, the strip having the tabs adhered thereto is unwound from the roll and laid on the roof. Thereafter, succeeding strips having tabs thereon are unwound from a roll and laid in overlapping fashion over each other, with the tabs of each succeeding sheet intermediate the tabs of the immediately preceding sheet so as to provide the shingle effect.
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.

Fig. 1 illustrates a roofing shingle preform in accordance with certain principles of the invention;
Fig. 2 is a cross-sectional view taken along the lines 2-2 of Fig. l;
Fig. 3 is a cross-sectional view taken along the lines 3-3 of Fig. 1;
Fig. 4 is a plan view showing an alternative embodiment of the novel roofing shingle preform;
Fig. 5 illustrates diagrammatically the process of manufacturing the novel preform of Fig. 1 and forming the same into a roll; and Fig. 6 illustrates installation of the novel shingle of Fig. 1 to a roof.

Referring now to the drawings and, in partic-ular, to Fig. 1, there is shown a roofing shingle - - -21~4362 _ - 4 -preform 10 which includes a strip 11 and a plurality of tabs 12 attached to the strip 11 in spaced fashion. The strip 10 is preferably formed of the novel, modified bitumen membrane disclosed in the copending application of John P. Hageman, disclosed above. More specifically, referring to Fig. 2, the strip 11 includes a core 13 formed of fiberglass or polyester and an overlying 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.
In a typical roofing shingle preform 10, the width Ws of the strip and the width WT of the tab are each eight inches, the length LT of the tabs may be 8, 10 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, as shown in Fig. 4, may be used to enhance the aesthetics of a roof shingled with the preform 10.
Advantageously, as 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 18 wherein the tabs 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 tabs thereto. It is not necessary that the entire surface area to which the tabs are going to be attached be coated. Only an area Wc extending from an upper edge 21 towards a bottom edge 19 (upper and bottom referring to the relative positioning to these edges when a strip of the preform shingle is laid on a ~I>F~

214~362 roof 22 (Fig. 6)), need be coated with the adhesive.
Preferably, the area Wc extends approximately half-way down the tab.
After exiting the station 18, the strip is wound into a roll 23. The length of the strip 11 in each roll is determined by the weight of the roll 23 that may be easily handled by a roofer during installation.
Typically, 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 asphalt primer and allowed to dry.
Thereafter, insulation panels (not shown) and a base sheet (not shown, but which may be formed from the novel bitumen membrane disclosed in the copending application of John P. Hageman referred to above) are attached to the underlying roof deck 24, using mechanical fasteners.
Alternatively, the insulation panels and base sheet may be attached using a hot asphalt process. Thereafter, 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 fasteners. More specifically, after laying of the course, the bottom portions of the tabs 12 (i.e., the portions below the area Wc) are lifted from the underlying strip 11 and the strip fastened to the underlying course using mechanical fasteners, such as nails 26. The tabs 12 are then lowered back onto the strip so they are flush with the underlying strip 11, an overlying course then laid and the process repeated.
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 shingle in any course overlaps a shingle in the second course below it. Typically, headlap with the ';PF-'~7?'i?7 preform 10 is 3 inches. In addition to overlapping the immediately preceding preform lOa, each succeeding preform (such 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 foregoing description, since the preform 10 is unwound from a roll, 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. Further, the ability to fold the tabs away from the underlying strip to enable nailing provides instantaneous sealing, thereby avoiding the necessity of relying on heat from the sun to effect sealing, while at the same time preventing any damage from weather which might occur prior to sealing.
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, polyester is preferred because fiberglass is too stiff.
Additionally, while other modifier resins may be employed, such as actactic polypropylene (APP), SBS
and SEBS resins are preferred because each, when modified with such resins, is amenable to being attached using asphalt adhesives, whereas such is not true of APP resins and asphalt adhesives are the preferred material for attaching the tabs 12 to a strip 10.
As will be appreciated, the present invention has been described in relation to a particular illustrative embodiment thereof. Many other variations c PP~ c-n ..

and processes will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited, not by the specific disclosure herein, but only by the appended claims.

"

Claims (28)

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 only a top portion of each tab is adhered to the underlying strip.
3. A roofing shingle preform as recited in claim 1, wherein only approximately the top half of each tab is adhered to its underlying strip.
4. A roofing shingle preform, as recited in claim 2, 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.
5. A roofing shingle preform, as recited in claim 4, 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.
6. A roofing shingle preform, as recited in claim 5, wherein the core is made of polyester.
7. A roofing shingle preform, as recited in claim 4, 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.
8. A roofing shingle preform, as recited in claim 7, 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.
9. A roofing shingle preform, as recited in claim 8, wherein the core of each tab is made of polyester.
10. A roofing shingle preform, as recited in claim 9, wherein the core of the strip is made of polyester.
11. A roofing shingle preform, as recited in claim 10, further including crushed aggregate in the modified bitumen layer of the strip and crushed aggregate in the modified bitumen layer of the tabs.
12. 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.
13. A method of manufacturing a roofing shingle preform, comprising:
(a) forming a strip comprised of a modified bitumen membrane;
(b) attaching to the strip, in spaced relationship, a plurality of tabs formed of a modified bitumen membrane; and (c) winding the strip, after attachment of the tabs thereto, into a roll.
14. A method of manufacturing a roofing shingle preform, as recited in claim 13, wherein in step (b) only the top portions of the tabs are attached to the strip.
15. A method of manufacturing a roofing shingle preform, as recited in claim 13, wherein in step (b) approximately the top half of each tab is attached to the strip.
16. A method of manufacturing a roofing shingle preform, as recited in claim 14, wherein the strip comprises a flat core having a top surface and a bottom surface and a bitumen layer on only the top surface.
17. A method of manufacturing a roofing shingle preform, as recited in claim 16, 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.
18. A method of manufacturing a roofing shingle preform, as recited in claim 14, 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.
19. A method of manufacturing a roofing shingle preform, as recited in claim 18, 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 manufacturing a roofing shingle preform, as recited in claim 19, wherein the core of the tab and the core of the strip are each formed of polyester.
21. A method of fabricating 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.
22. The method of fabricating a shingle roof, as recited in claim 21, wherein only the top portion of each of the tabs is attached to the strip and wherein after a course of the preform is attached to the roof, the tabs of each course are lifted to expose the underlying strip and mechanical fasteners inserted into the strip to attach the strip to an underlying course.
23. A method of fabricating a shingle roof as recited in claim 22, wherein approximately the top half of each of the tabs is attached to the strip.
24. A method of fabricating a shingle roof, as recited in claim 22, wherein the strip comprises a flat core having a top surface and a bottom surface and a bitumen layer on only the top surface.
25. A method of fabricating a shingle roof, as recited in claim 24, 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.
26. A method of fabricating a shingle roof, as recited in claim 22, 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.
27. A method of fabricating a shingle roof, as recited in claim 26, 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.
28. A method of fabricating a shingle roof, as recited in claim 27, wherein the core of the tab and the core of the strip are each formed of polyester.
CA 2144362 1994-03-31 1995-03-10 Roofing shingle preform and methods of manufacturing and using the same Abandoned CA2144362A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US22140294A 1994-03-31 1994-03-31
US08/221,402 1994-03-31

Publications (1)

Publication Number Publication Date
CA2144362A1 true CA2144362A1 (en) 1995-10-01

Family

ID=22827683

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2144362 Abandoned CA2144362A1 (en) 1994-03-31 1995-03-10 Roofing shingle preform and methods of manufacturing and using the same

Country Status (1)

Country Link
CA (1) CA2144362A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11021876B2 (en) 2017-12-05 2021-06-01 Owens Corning Intellectual Capital, Llc Shingles with a thick appearance

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11021876B2 (en) 2017-12-05 2021-06-01 Owens Corning Intellectual Capital, Llc Shingles with a thick appearance
US11761210B2 (en) 2017-12-05 2023-09-19 Owens Corning Intellectual Capital, Llc Shingles with a thick appearance

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Legal Events

Date Code Title Description
FZDE Discontinued
FZDE Discontinued

Effective date: 20000310