US20150089895A1

US20150089895A1 - Shingle with dual sealant

Info

Publication number: US20150089895A1
Application number: US14/043,798
Authority: US
Inventors: Olan Leitch
Original assignee: Building Materials Investment Corp
Current assignee: Building Materials Investment Corp
Priority date: 2013-10-01
Filing date: 2013-10-01
Publication date: 2015-04-02

Abstract

The present disclosure relates, according to some embodiments, to articles, systems, methods of use, methods of manufacturing, and methods of packing roofing shingles with dual sealants. A shingle may comprise, in some embodiments, a headlap region comprising a top headlap surface and a back headlap surface; a buttlap region comprising a top buttlap surface and a back buttlap surface. A top headlap surface may comprise a first sealant and/or a back headlap surface may comprise a second sealant.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates, in some embodiments, to articles, systems, and methods for roofing a structure including, for example, shingles comprising a first and second sealant.

BACKGROUND OF THE DISCLOSURE

Roofing materials such as shingles may be used to clad a structural surface such as a roof with a roofing substrate. Such shingles may have a sealant that allows a shingle to adhere to another shingle, a structure, or a substrate. If the adhesion is too weak, a shingle may become loose and may result in structural instability of an entire roofing system. Structurally unstable roofing systems may create hazardous conditions for occupants in the building on which the roofing system is assembled. Structurally unstable roofing systems may also be costly to repair. Shingles with weak sealants also may not be appropriate for roofing structures with steep slopes or roofing systems that may often be subjected to strong winds or high heat conditions.
Roofing materials such as shingles may be sold in bulk and may be packaged as assemblies. Assemblies may not be packaged in the most secure or space-efficient manner. Inefficient usage of space may increase packaging costs and shipping costs. Improperly secured shingles may be damaged during shipping. Another problem that occurs in packaging of shingles is that a sealant of a shingle may be inadvertently exposed to another surface during packaging or while inside the packaging. Inadvertent exposure may result in a sealant adhering to an undesired surface. As a result, an adhesive quality of a sealant may be compromised and the shingle may become unusable.

SUMMARY

Accordingly, a need has arisen for improved shingles that have greater bond or sealant strength, increased stability, and greater ease and space-efficiency in packaging. More specifically, it may be desirable to have a shingle assembly that promotes space-efficient packaging and prevent inadvertent adherence of a sealant to an undesired surface. It may also be desirable to have a shingle system wherein shingles may form strong bonds or a strong adhesion.
The present disclosure relates, according to some embodiments, to articles, systems, methods of use, methods of manufacturing, assemblies of, and methods of packing roofing shingles for cladding a structure. For example, a dual sealant shingle may comprise a headlap region with a top headlap surface and a back headlap surface; a buttlap region with a top buttlap surface and a back buttlap surface. A top headlap surface may comprise a sealant (e.g., a first sealant). A back headlap surface may comprise a sealant (e.g., a second sealant). A sealant may be a conditional sealant, in some embodiments. For example, a sealant may be formulated to become adhesive (e.g., tacky, sticky) upon contact with another composition (e.g., a sealant of like or different composition on another shingle). In some embodiments, first and/or second sealants independently may have substantially stripe-shaped geometries. A sealant may be positioned on a top headlap surface closer to the middle of the shingle than the upper edge of the shingle in some embodiments. For example, a sealant may be positioned on a top headlap surface near (e.g., adjacent) and/or substantially parallel to the lower edge of the headlap and/or upper edge of the buttlap. A sealant may be positioned on a back buttlap surface closer to the lower edge of the shingle than the middle of the shingle, in some embodiments. For example, a sealant may be positioned on a back buttlap surface near (e.g., adjacent) and/or substantially parallel to the lower edge of the shingle (e.g., opposite the headlap and/or parallel to the bottom edge of the buttlap). First and/or second sealants independently may have substantially the same shape and/or substantially the same size according to some embodiments. A first sealant may be about 0.2 inches to about 0.6 inches wide, a second sealant may be about 0.2 inches to about 0.6 inches wide or a first sealant and a second sealant may be each about 0.2 inches to about 0.6 inches wide. In some embodiments, a first sealant and a second sealant may have substantially the same composition.
The present disclosure relates, in some embodiments, to roofing systems for cladding a structure. For example, a roofing system may comprise a first dual sealant shingle and a second dual sealant (e.g., each as described above), wherein the first sealant of the first shingle is aligned with and contacts the second sealant of the second shingle. A roofing system may further comprise a third dual sealant shingle, wherein the second sealant of the first shingle is aligned with and contacts the first sealant of a third shingle. A second shingle may be laterally offset from the first shingle and/or a third shingle, if present, may be aligned with a first shingle or laterally offset from a first and/or second shingle. In some embodiments, contact between sealants may be substantially coextensive, for example, where sealant strips are laterally and vertically aligned, or partial, for example, where sealant strips are vertically aligned and laterally offset.
According to some embodiments, the present disclosure relates to methods for cladding a structure comprising a substrate (e.g., a roof deck). For example, a method may comprise providing a first dual sealant shingle and a second dual sealant (e.g., each as described above) and/or contacting the first sealant of the first shingle and the second sealant of the second shingle. A method may further comprise, in some embodiments, providing a third shingle, and contacting the second sealant of the first shingle and the first sealant of a third shingle. A method may comprise positioning a first dual sealant shingle, a second dual sealant, and a third dual sealant (e.g., each as described above), wherein a lateral edge of the first shingle abuts a lateral edge of the second shingle, the first sealant of the first shingle is collinear with the first sealant of the second shingle, a portion of the second sealant of the third shingle contacts a portion of the first sealant of the first shingle, and/or a portion of the second sealant of the third shingle contacts a portion of the first sealant of the second shingle.
The present disclosure relates, in some embodiments, to methods for manufacturing a shingle. For example, a method of manufacturing a shingle may comprise (a) providing a shingle comprising a headlap region (e.g., comprising a top headlap surface and a back headlap surface) and a buttlap region (e.g., comprising a top buttlap surface and a back buttlap surface), (b) providing a first conditional sealant (e.g., on the top headlap surface), and/or (c) providing a second conditional sealant (e.g., on the back buttlap surface), wherein the first conditional sealant and/or the second conditional sealant are formulated to have substantially no adhesiveness alone, but become adhesive upon contact with the other. A manufacturing method may comprise at least partially covering (e.g., substantially covering, covering) the first sealant with a release tape, at least partially covering the second sealant with a release tape, or at least partially covering the first sealant and the second sealant with a release tape.
The present disclosure relates, in some embodiments, to assemblies of shingles (e.g., non-adhered shingles). An assembly of shingles may comprise, for example, a first dual sealant shingle and a second dual sealant (e.g., each as described above), wherein (a) the top surface of the first shingle may contact back surface of the second shingle, (b) the outer edges of the first and second shingles may be at least partially aligned (e.g., substantially aligned, aligned), and (c) the second shingle may be arranged 180° from the first shingle (e.g., the upper edge of the first shingle is adjacent to the lower edge of the second shingle and/or the upper edge of the second shingle is adjacent to the lower edge of the first shingle). In some embodiments, an assembly of shingles may comprise a first dual sealant shingle and a second dual sealant (e.g., each as described above), wherein (a) the top headlap surface of the first shingle may be at least partially aligned (e.g., substantially aligned, aligned) with the back buttlap surface of the second shingle, (b) the top headlap surface of the first shingle may at least partially contact (e.g., substantially contact, contact) the back buttlap surface of the second shingle, (c) the top buttlap surface of the first shingle may be at least partially aligned (e.g., substantially aligned, aligned) with the back headlap surface of the second shingle, (d) the top buttlap surface of the first shingle may at least partially contact (e.g., substantially contact, contact) the back headlap surface of the second shingle, and/or (e) the second shingle may be arranged 180° from the first shingle (e.g., the tabs of the first shingle and the tabs of the second shingle face opposite directions).
According to some embodiments, the present disclosure provides methods for packing assemblies of shingles. For example, a method may comprise providing a first dual sealant shingle and a second dual sealant (e.g., each as described above) and positioning the first and second shingle wherein (a) the top surface of the first shingle may contact back surface of the second shingle, (b) the outer edges of the first and second shingles may be at least partially aligned (e.g., substantially aligned, aligned), and (c) the second shingle may be arranged 180° from the first shingle. A packing method may comprise, according to some embodiments, (a) positioning a top headlap surface of a first shingle to be at least partially aligned (e.g., substantially aligned, aligned) with a back buttlap surface of a second shingle, (b) positioning the top headlap surface of the first shingle to at least partially contact (e.g., substantially contact, contact) the back buttlap surface of the second shingle, (c) positioning a top buttlap surface of the first shingle to be at least partially aligned (e.g., substantially aligned, aligned) with a back headlap surface of the second shingle, and/or (d) positioning the top buttlap surface of the first shingle to at least partially contact (e.g., substantially contact, contact) the back headlap surface of the second shingle.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the disclosure may be understood by referring, in part, to the present disclosure and the accompanying drawings, wherein:

FIG. 1A illustrates a top view of a shingle according to an example embodiment of the disclosure;

FIG. 1B illustrates a back view of the shingle shown in FIG. 1A;

FIG. 2A illustrates a back perspective view of an assembly of shingles according to an example embodiment of the disclosure;

FIG. 2B illustrates a profile view of the assembly of shingles shown FIG. 2A;

FIG. 3A illustrates a top perspective view of an assembly of shingles according to an example embodiment of the disclosure;

FIG. 3B illustrates a profile view of the assembly of shingles shown in FIG. 3A;

FIG. 4A illustrates a top view of a shingle according to an example embodiment of the disclosure;

FIG. 4B illustrates a back view of the shingle shown in FIG. 4A;

FIG. 4C illustrates a profile view of an assembly of shingles according to an example embodiment of the disclosure;

FIG. 5A illustrates a profile view of an assembly of shingles according to an example embodiment of the disclosure;

FIG. 5B illustrates a more detailed view of a portion of the assembly of shingles shown in FIG. 5A;

FIG. 5C illustrates a more detailed view of a portion of the assembly of shingles shown in FIG. 5A;

FIG. 6 illustrates a profile view of an assembly of shingles according to an example embodiment of the disclosure;

FIG. 7 illustrates a top view of two shingles aligned according to an embodiment of the disclosure.

Table 1 below includes the reference numerals used in this application. Similar structures share matching tens and ones digits.

TABLE 1

Feature Name	FIG. 1A	FIG. 1B	FIG 2A	FIG. 2B	FIG. 3A	FIG. 3B	FIG. 4A

Shingle System
			200	200	400	400
Shingle	101	101	201, 301	201, 301	401, 501	401, 501	601
Headlap Region	102	102			402, 502	402, 502	602
Buttlap Region	104	104			404, 504	404, 504	604
Top Surface			205, 305	205, 305		405, 505
Top Headlap Surface	106				406, 506	406, 506	606
Back Surface			207, 307	207, 307		407, 507
Back Headlap Surface		108				408, 508
Top Buttlap Surface	110				410, 510	410, 510	610
Sealant	111			311	411, 511	411, 511	611
Back Buttlap Surface		112				412, 512
Sealant		113	213			413, 513
Tape	114				414, 514	414, 514	614
Tape		116				416, 516
Tabs	118	118			418, 518		618
Spacings	120	120			420, 520		620
First Layer							622
Second Layer							624
Upper Edge	130	130					630
Lower Edge	131	131					631

Feature Name	FIG. 4B	FIG. 4C	FIG. 5A	FIG. 5B	FIG. 5C	FIG. 6	FIG. 7

Shingle System		600	700			900	1100
Shingle	601	601	701, 801	701, 801	701, 801	901, 1001	1101, 1201
Headlap Region	602	602				902, 1002
Buttlap Region	604	604				904, 1004
Top Surface			805
Top Headlap Surface		606	806	806	706, 806	906, 1006
Back Surface			707
Back Headlap Surface	608	608	708	808	708, 808	908, 1008
Top Buttlap Surface		610	810	710	710, 810	910, 1010
Sealant		611, 611′	711, 811		711, 811	911, 1011	1111, 1211
Back Buttlap Surface	612	612	712	712	712, 812	912, 1012
Sealant	613	613		713		913, 1013
Tape		614, 614′	814	814		914, 1014	1114, 1214
Tape	616	616	716		716, 816	916, 1016
Tabs							1118, 1218
Spacings							1120
First Layer	622	622				922, 1022
Second Layer	624	624				924, 1024
Upper Edge	630		730			930, 1030
Lower Edge	631		831			931, 1031

DETAILED DESCRIPTION

The present disclosure relates, according to some embodiments, to articles, systems, methods of use, methods of manufacturing, and methods of packing roofing shingles for cladding a structure. More specifically, the present disclosure relates, in some embodiments, to shingles comprising a first and second sealant. Benefits of articles, systems, and methods may include, in some embodiments, increased sealant strength, increased stability, greater ease of packaging, and/or greater ease of assembly.

Articles

The present disclosure relates, according to some embodiments, to shingles (e.g., asphalt shingles) with dual sealants. According to some embodiments, a shingle with dual sealants may comprise a headlap region, a buttlap region, a first sealant, and a second sealant. A headlap region may comprise a top headlap surface and a back headlap surface. A buttlap region may comprise a top buttlap surface and a back buttlap surface. A top headlap surface may comprise a first sealant. A back headlap surface may comprise a second sealant.
According to the present disclosure, various materials may be suitable for use as a composition of a headlap region, buttlap region, first sealant, or second sealant. For example, a headlap or buttlap region may comprise any number of materials such as a metallic substrate (e.g., steel, an alloy, copper, aluminum, and combinations thereof), a polymeric substrate (e.g., thermoplastic polyolefin), or asphalt. In some embodiments, an article may be or may comprise an asphalt shingle with dual sealants (e.g., dual conditional sealants). First and second sealants may have compositions that are the same or different. According to the present disclosure, materials for various components may be varied as desired or required.
Various types or structures of shingles may be formed with a dual adhesive. For example, shingles structures may include, for example, 3-tab and/or dragon's tooth configurations.
A sealant bond strength may be greater on a surface to which it is factory-applied. When a sealant is factory-applied to surface, a sealant may exhibit a stronger adhesive quality on the side to which it was factory-applied to than on the side to which it is adhered to after factory manufacturing (e.g., after adhesive has dried, set, and/or cured). For example, an adhesive may be originally applied to a first surface and a second surface may be later (e.g., after the adhesive has cured) contacted with the adhesive to form a bond. Upon separation of these first and second surfaces, the break may be more likely to occur between the adhesive and the second surface than between the adhesive and the original surface. Accordingly, factory-applied sealants may be said to form a stronger bond on the side to which they were originally-applied.
The present disclosure may provide, in some embodiments, improved bond strength by joining shingles with an adhesive-adhesive bond. For example, a first sealant and a second sealant applied to or disposed on opposing sides of adjacent shingles (e.g., adjacent top and back surfaces, or adjacent buttlap and headlap regions). According to some embodiments, the first and second sealant may contact each other and form a bond. A sealant-sealant bond may be about as strong or stronger than an original sealant-shingle bond, according to some embodiments. Thus, a shingle joined to adjacent shingles through one or more adhesive-adhesive bonds may have greater bond strength and/or greater adhesion over shingles or systems joined without adhesive-adhesive bonds, those joined only with shingle-sealant-shingle bonds).
According to some embodiments, a first sealant and/or a second sealant may comprise material that does not become adhesive until contact or mating with another sealant. For example, on its own, a first sealant and/or a second sealant may not have an adhesive quality. An absence of adhesiveness may reduce problems associated with a shingle's adhesive region adhering to or affixing to undesired material. Such undesired material may include a wrong shingle surface, dust and specks, packaging material of the shingle itself, and others. A first sealant and/or a second sealant may only become adhesive, according to some embodiments, upon contact or upon mating with a particular material. For example, in some embodiments, a top headlap surface may comprise a first sealant (“sealant A”) and a back headlap surface may comprise a second sealant (“sealant B”). Sealant A may be chosen such that it does not become adhesive until contact with a material of sealant B. Sealant B independently may be a material that does not become adhesive until contact with a material of sealant A. Thus, sealant A and sealant B would not become adhesive until contact with one another. Accordingly, sealant A on a top headlap surface of one shingle may selectively mate with sealant B on a top buttlap surface of another shingle. Conditional sealants (e.g., contact-activated adhesive materials) may be selected and/or formulated, according to some embodiments, to become adhesive in seconds, minutes, hours, or days as desired.
In some embodiments, a first sealant or second sealant may vary in composition or materials. Different sealants may be selected, according to some embodiments, as being more appropriate or desirable for use in combination with particular materials used for a buttlap and/or headlap regions of a shingle. In some embodiments, a first sealant and second sealant may be a laminate adhesive, bituminous based adhesive, an asphalt adhesive, a modified asphalt adhesive, or combinations thereof. In some embodiments, a first sealant and second sealant may comprise an active component, such as polyester acrylate, resorcinol, phenol, epoxy, isocyanate acrylic, and the like. A conditional sealant composition may not be operative as an adhesive unless it is in contact with a mated conditional sealant composition. Mated conditional sealants may have the same composition or different compositions. In some embodiments, a first conditional sealant and a second conditional sealant become adhesive upon contact alone (e.g., not upon exposure to heat and/or radiation).
According to some embodiments, a first sealant and second sealant may each vary in geometry and/or surface area. In some embodiments, a first sealant and second sealant independently may each comprise a substantially stripe-shaped geometry. A first sealant and second sealant may or may not have the same shape and/or size as one another. In some embodiments, having a first sealant and a second sealant of either different sizes or same sizes may be beneficial or promote proper alignment of the two features under different circumstances.
A first sealant and second sealant, in some embodiments, may each be substantially covered with a release tape. Release tape may contact sealant, for example, during packing and shipping. In some embodiments, release tape may prevent undesired exposure of a sealant. Such undesired exposure may be to materials including a wrong shingle surface, dust and specks, packaging material of the shingle itself, and others.
According to some embodiments, release tape may vary in composition or materials. Different types of release tapes may be selected as being more appropriate or desirable for use in combination with particular materials used for a first sealant and/or second sealant. According to some embodiments, release tape may be disposed on shingle in a non-removable manner. In some embodiments, release tape may be removable.
According to some embodiments, a first sealant and/or second sealant independently may have a width of about 0.2 inches to about 0.6 inches. A first sealant and/or a second sealant independently may be, in some embodiments, 0.38 inches wide. A sealant may swell, in some embodiments, upon contact with another sealant. For example, a conditional sealant may swell up to about 100% upon contact with another conditional sealant material. In some embodiments, a release tape may be sized according to the swellability of conditional sealants present. For example, a release tape strip may be about 2 to about 5 times as wide as a conditional sealant strip. In some embodiments, a width of a release tape may be greater than twice the width of a conditional sealant. For example, a release tape may be about 1¼″ wide and a sealant may be about ⅜″ wide. An over-sized release tape may be desirable, for example, where a conditional sealant may have some tendency to swell during shipping, despite the absence of contact with a corresponding conditional sealant. A release tape may be about 1.25 inches wide and span up to about the full length of a shingle. A release tape and/or a sealant may be positioned on a shingle to be approximately centered relative to each other.
Dual sealants may be applied, according to some embodiments, to various roofing shingles. Shingles may contain one or more tabs in a buttlap region. Tabs may be defined by inter-tab openings of particular widths. Inter-tab openings and/or tabs may have any desired size or shape to suit aesthetic and/or functional goals. For example, dragon's tooth shingles may have tabs with a generally trapezoidal configuration.
According to some embodiments, a roofing shingle may comprise sealant strips. Sealant strips may be disposed on a back buttlap surface and/or a top headlap surface. In some embodiments, a roofing shingle may comprise sealant strips on both a back buttlap surface and a top headlap surface. A sealant strip, in some embodiments, may extend laterally across a shingle generally parallel to a top and/or bottom edge. A sealant strip may mark the presence and/or location of a release tape on the opposite surface of a shingle according to some embodiments. Sealant strips may be deposited as a solid line and/or as a dashed line.

Systems

The present disclosure relates, according to some embodiments, to roofing systems comprising shingles with dual sealants. In some embodiments, a first sealant and second sealant of shingles may comprise material that does not become adhesive until contact with another sealant. In some embodiments, a first sealant and second sealant of shingles may each vary in geometry and/or surface area. In some embodiments, a first sealant and second sealant of shingles may each be substantially covered with a release tape. In some embodiments, a first sealant and second sealant may have a width of about 0.2 inches to about 0.6 inches.
A roofing system, in some embodiments, may be configured such that up to about 100% of a substrate (roof deck) is covered by at least one layer of shingles in accordance with the present disclosure. This may be achieved, for example, by arranging each shingle such that it overlaps at least a portion of a shingle immediately below. More specifically, at least a portion of a contiguous upper region of a first shingle may overlap at least a portion of a contiguous lower region of a second shingle.
According to some embodiments of the present disclosure, a roofing system may comprise a plurality of shingles wherein the overlap is affixed through the use of a first sealant and a second sealant. In some embodiments, a first sealant provided on a top headlap surface of one shingle may contact a second sealant provided on a back headlap surface of another shingle. Thus, a top headlap surface of a first shingle may be overlapped by a portion (e.g., a lower portion) of a back headlap surface of a second shingle.
In some embodiments, a system may be configured and arranged for use on any type of roofing decking and at any pitch, slope, or angle. Dual sealant shingle systems may have, according to some embodiments, stronger bonds (e.g., inter-shingle bonds) than single sealant systems. Stronger adhesion in a system may prevent shingles from becoming loose and may prevent structural instability of roofing systems. Dual sealant shingle systems may include shingle A-sealant-A-sealant-B-shingle B bonds. Bond strength between shingles bonded with a shingle-sealant-sealant-shingle bond may be assessed by any desirable metric. In some embodiments, a shingle-sealant-sealant-shingle bond may be strong enough to meet or exceed wind resistance requirements (e.g., building code). For example, dual sealant shingles with sealant-sealant bonds near the lower edge may be meet or exceed hurricane performance requirements (e.g., resist uplift and/or separation under sustained winds of about 130 miles per hour).

Methods of Use

The present disclosure relates, according to some embodiments, to methods for cladding a structure comprising a substrate (e.g., a roof deck). More specifically, methods for cladding a substrate may comprise securing shingles to a substrate (e.g., dual sealant shingles). According to some embodiments of the present disclosure, a method of cladding a structure may comprise contacting a first sealant of one shingle with a second sealant of another shingle. For example, a method may include optionally applying a first dual sealant shingle to a roofing substrate or otherwise providing a roofing substrate with an affixed first dual sealant shingle. A method may comprise removing tape, if present, from a top headlap surface sealant of the first shingle and/or a back headlap surface sealant of a second dual sealant shingle. Contacting sealants in adjacent shingles may include, according to some embodiments, positioning a second shingle with respect to a first shingle so that the back headlap sealant of the second shingle is aligned with the top headlap sealant of the first shingle. Once positioned, the second shingle may be laid on the first shingle, thereby bringing the first and second sealants into contact. A method may comprise removing tape, if present, from a top headlap surface sealant of the second shingle and/or a back headlap surface sealant of a third dual sealant shingle, positioning the third shingle with respect to the second shingle so that the back headlap sealant of the third shingle is aligned with the top headlap sealant of the second shingle, and/or laying the third shingle on the second. A method may comprise laterally offsetting successive shingles, for example, to avoid forming vertical seams that could admit water.
A method may comprise using a guide strip disposed on a shingle to align a shingle with another shingle. A method may comprise aligning a guide strip on a first shingle with a sealant strip on a second shingle. Aligning may include, in some embodiments, positioning a guide strip on a first shingle substantially parallel to and substantially immediately over a sealant strip on a top headlap surface of a second shingle.

Methods of Making

The present disclosure relates, according to some embodiments, to methods of making or manufacturing shingles with dual sealants suitable for cladding a structure comprising substrate. Methods may comprise providing a shingle with a headlap region and a buttlap region, wherein a headlap region may comprise a top headlap surface and a back headlap surface, and wherein a buttlap region may comprise a top buttlap surface and a back buttlap surface. Methods may further comprise providing (e.g., applying, depositing, spraying, injecting) a first sealant on a top headlap surface, and/or providing (e.g., applying, depositing, spraying, injecting) a second sealant on a back headlap surface.
A method may comprise forming a desired shape for the shingle using a desired material. A desired shape may be substantially rectangular or mat-like in geometry. A desired material may be a metallic substrate (e.g., steel, an alloy, copper, aluminum, and combinations thereof), a polymeric substrate (e.g., thermoplastic polyolefin), or asphalt.
After a desired shape is formed from the desired material, a method may comprise forming tabs on a buttlap region of a shingle. In some embodiments, tabs may be formed by chiseling, machining, or otherwise mechanically removing material disposed in intended spacings between intended tabs of the buttlap region. In some embodiments, tabs may be formed by manufacturing a shingle in an appropriate mold that may be shaped with corresponding tab designs.
After a desired shape is formed from the desired material, a method may comprise disposing sealants on a shingle. Sealants may be disposed on a back buttlap surface and/or a top headlap surface. Sealants may be formed along a length of the shingle. In some embodiments, a roofing shingle may comprise sealants on both a back buttlap surface and a top headlap surface. In some embodiments, disposing a sealant on a shingle may comprise contacting a surface of a shingle with a material comprising a sealant and/or a conditional sealant with a shingle and, optionally, at least partially curing and/or drying the material. In some embodiments, contacting a shingle surface and a sealant may comprise forming a sealant bead on the shingle surface, depositing sealant on the shingle surface, applying sealant on the shingle surface, injecting sealant into the surface, and/or forming a pattern of sealant on the shingle surface along at least a portion of the shingle.
After a desired shape is formed from the desired material, a method may comprise disposing release tape on a shingle. Release tape may be disposed on a back surface and/or a top surface. Release tape may be formed along a length of the shingle. In some embodiments, a roofing shingle may comprise release tape on both a back surface (e.g., a back headlap surface) and a top surface (e.g., a top headlap surface). In some embodiments, disposing a release tape on a shingle may comprise adhering a release tape using an adhesive. In some embodiments, release tape may be removable prior to installation of a roofing system. In some embodiments, release tape may be disposed on shingle and removable prior to installation may not be necessary.

Assembly of Articles

The present disclosure relates, according to some embodiments, to assemblies of articles that may be wrapped, stacked, and/or shipped (e.g., to an installation site). Assemblies of articles may comprise shingles with dual sealants configured and arranged to reduce undesired binding or contact of sealant to other materials. An assembly may comprise a first shingle and a second shingle, wherein the top surface of the first shingle contacts the back surface of the second shingle. To avoid premature contact between mateable sealant strips, however, the second shingle may be rotated 180° relative to its position upon installation according to some embodiments. For example, a top buttlap surface of a first shingle may be adjacent to and/or contact a back headlap surface of a second shingle. A top headlap surface of a first shingle may be adjacent to and/or contact a back buttlap surface of a second shingle. Successive shingles may be stacked in this alternating pattern, each rotated about 180° relative to the last. In an alternating configuration, tabs of successive shingles face opposite directions.
In some embodiments, a tape strip on the top headlap surface of a first shingle may be adjacent to and/or contact a sealant strip on a back buttlap surface of a second shingle. In some embodiments, a sealant on a top headlap surface of a first shingle may be positioned to be adjacent to and/or contact a guide strip on a back surface (e.g., headlap) of a second shingle.
The present disclosure relates, in some embodiments, to assemblies of articles (e.g., packages of shingles) that may be space-efficient and may prevent inadvertent adhering of a sealant to an undesired surface. Since a first and second sealant, in some embodiments, may not become adhesive until contact with another sealant, the assemblies of the present disclosure may prevent unintended adherence of a sealant to an undesired surface. For example, positioning a top headlap surface of a first shingle against a back buttlap surface of a second shingle (e.g., with oppositely facing tabs) may not expose a first sealant and a second sealant to one another. Similarly, positioning a top buttlap surface of a first shingle against a back headlap surface of a second shingle, may not expose a first sealant and a second sealant to one another.

Methods of Packing

The present disclosure relates, according to some embodiments, to methods of packing articles (e.g., dual sealant shingles). In some embodiments, a method may comprise providing a plurality of shingles, wherein each shingle comprises a headlap region comprising a top headlap surface and a back headlap surface, and a buttlap region comprising a top buttlap surface and a back buttlap surface. A method may comprise providing a first sealant on a top headlap surface of a shingle and providing a second sealant on a back headlap surface of the shingle. A method may comprise, in some embodiments, positioning a second shingle over a first shingle and contacting the back surface of the second shingle to the top surface of the first shingle. For example, a method may include positioning a first and/or a second shingle so a top headlap surface of the first shingle is adjacent to and/or contacts a back buttlap surface of the second shingle, a top buttlap surface of the first shingle is adjacent to and/or contacts back headlap surface of the second shingle, tabs of the first and second shingle face away from each other, the upper edge of the first shingle is aligned with and adjacent to the lower edge of the second shingle, and/or the upper edge of the second shingle is aligned with and adjacent to the lower edge of the first shingle. A packing method may comprise contacting a top surface of a first shingle with a back surface of a second shingle. The headlap of the first shingle may contact the buttlap of the second shingle. The buttlap of the first shingle may contact the headlap of the second shingle. Tabs of the first and second shingles may be oppositely and outwardly positioned. For example, tabs (or dragon teeth) of each successive shingle may be positioned along opposite long edges in a stack of shingles. In some embodiments, positioning may include moving a first shingle, moving a second shingle, or moving both a first shingle and a second shingle to a desired position. For example, a method may include positioning a loose second shingle over a packed first shingle.
In some embodiments, a method may include positioning first and second shingles so a tape on a top headlap surface of a first shingle may be adjacent to and/or contact a sealant on a back buttlap surface of a second shingle. In some embodiments, a sealant on a top headlap surface of a first shingle may be adjacent to and/or contact a tape on a back buttlap region of a second shingle.

Specific Example Embodiments

Specific example embodiments of a shingle with dual sealants are illustrated in FIGS. 1-7. FIG. 1A illustrates a top view of shingle 101 according to an example embodiment of the disclosure. FIG. 1B illustrates a back view of shingle 101 shown in FIG. 1A. Shingle 101 may comprise headlap region 102 and buttlap region 104. Headlap region 102 may comprise top headlap surface 106 and opposite-facing back headlap surface 108. Buttlap region 104 may comprise top buttlap surface 110 and oppositely facing back buttlap surface 112. As seen in FIG. 1A, top headlap surface 106 may include sealant 111 and tape 114. As seen in FIG. 1B, back headlap surface 108 may include tape 116. Back buttlap surface 112 may comprise sealant 113 positioned along the lower edges of tabs 118. As seen in FIG. 1A and FIG. 1B, in some embodiments, sealant 111 and sealant 113 may have substantially stripe-shaped geometries. In some embodiments, sealant 111 and sealant 113 may have the same shape and size.
Buttlap region 104 of shingle 101 has three tabs 118 that extend from headlap region 102. Tabs 118 are interspersed from one another by spaces 120. Shingle 101 may have a different number of tabs 118 in a buttlap region. Furthermore, each of tabs 118 may have any particular shape or size needed to suit aesthetical or functional goals. For example, a tab shape may be substantially trapezoidal to achieve a dragon tooth shingle. Similarly, each of spacings 120 may have any particular shape or size needed to suit aesthetical or functional goals. Variations may be made to a shape, size, and number of tabs 118 and spacings 120 to buttlap region 104 of shingle 101 as desired or required.
FIG. 2A and FIG. 2B illustrate a back perspective view and profile view, respectively, of shingle system 200 according to embodiments of the disclosure. FIG. 2A and FIG. 2B illustrate how two shingles, shingle 201 and shingle 301, may be aligned to form roofing system 200. Shingle 201 may have back surface 207 and top surface 205. Similarly, shingle 301 may have back surface 307 and top surface 305. Shingle 201 may have sealant 213 on back surface 207. Shingle 301 may have sealant 311 on top surface 305. FIG. 2A illustrates a back perspective view of how sealant 213 and sealant 311 may be aligned prior to contact. FIG. 2B illustrates a profile view of how sealant 213 and sealant 311 may be aligned prior to contact. In some embodiments, sealant 213 and sealant 311 may not become adhesive until contact or mating with one another. When sealant 213 and sealant 311 are aligned properly, they may be affixed to one another through direct contact to form a strong adhesive bond (e.g., about as strong as the bond between 213 and 201, about as strong as the bond between 311 and 301). In some embodiments, sealant 213 and sealant 311 may each have a release tape (not pictured) prior to installation. Release tapes may be applied during a manufacturing process of shingles 201, 301. Release tapes may reduce (e.g., prevent) unintended exposure of an adhesive to undesired materials such as another shingle, a wrong surface or region of a target shingle, dust and specks, and others.
Various features present on shingles may be included on shingle 201 and shingle 301 as seen in FIG. 2A and FIG. 2B. For example, shingles 201 and 301 may be solid as shown in FIG. 2A and FIG. 2B or they may include tabs of any desired size, spacing, or shape. Shingle 201 may lack an adhesive strip on its top as shown (e.g., where it is to be the uppermost or last shingle to be applied to a sealant substrate) as shown or it may include a sealant strip. Also, shingle 301 may lack a sealant strip on its back as shown (e.g., where it is to be applied directly to a roofing substrate) as shown or it may include a sealant strip.
FIGS. 3A-3B illustrate shingle system 400 according to some embodiments of the disclosure. FIG. 3A illustrates a top perspective view of shingle system 400. As seen in FIG. 3A, shingle 401 and shingle 501 may be positioned (e.g., laterally and/or vertically offset as desired) for assembly on a roof. In FIG. 3A both shingle 401 and shingle 501 are viewed from the top. Shingle 401 may have headlap region 402 and buttlap region 404. From the perspective of FIG. 3A, top headlap surface 406 and top buttlap surface 408 are visible. Buttlap region 404 may comprise a plurality of tabs 418 that may be defined, in part, by spacings 420. Top headlap surface 406 may have sealant 411 affixed to it. Shingle 401 may also have another sealant (e.g., sealant 413) on its back buttlap region, which is not be visible from the perspective of FIG. 3A. Shingle 501 may have headlap region 502 and buttlap region 504. From the perspective of FIG. 3A, top headlap surface 506 and top buttlap surface 508 are visible. Buttlap region 504 may comprise a plurality of tabs 518 that may be defined, in part, by spacings 520. Top headlap surface 506 may have sealant 511 affixed to it. In some embodiments, a sealant (e.g., sealant 413) on a back buttlap region of shingle 401 may align with sealant 511 on top headlap surface 506 of shingle 501. Two sealants may initially be factory-applied to the respective shingles on which they are disposed. This may allow each of the sealants to form a strong bond with the shingle to which they are applied. Each of two sealants may not become adhesive until they are in contact with one another. For example, they may be adhesive when factory-applied to a shingle (e.g., so it may bind the shingle to which it is applied), but thereafter, the outer surface may have little or no “stickiness” unless/until contact is made with another sealant. Contact may be achieved through alignment (e.g., approximate alignment, substantial alignment, exact alignment) of the two sealants, which may have substantially striped-shaped geometries. In some embodiments, each sealant's size and shape may be independently selected. For example, any two sealants may have the same size and the same shape, the same shape by different sizes, the same sizes, but different shapes, or different sizes and different shapes.
FIG. 3A depicts the positions of only two shingles. Specifically, shingle 401 is vertically offset to align sealants 413 and 511 and laterally offset such that spacings 420 overlay tabs 518. Additional shingles may be positioned in like manner such that a number of shingles are used to form of roof covering. For example, a third shingle may be positioned over shingle 401, such that a sealant on a back buttlap of a third shingle may be aligned with and affixed to sealant 411 on top headlap surface 406 of shingle 401. By arranging each shingle such that it overlaps at least a portion of a shingle immediately below, a roofing system may be established that substantially covers 100% of a substrate on a structure.
FIG. 3B illustrates a profile view of shingle system 400 according to embodiments of the present disclosure. As shown, buttlap 404 and a lower portion of headlap 402 may contact headlap 502-surface 412 and a lower portion of surface 408 may contact surface 506. Back buttlap surface 412 contacts top headlap surface 506 below tape 514. Shingle 401 and shingle 501 may be positioned such that sealant 413 on back surface 407 of shingle 401 may be aligned with sealant 511 on top surface 505 of shingle 501 as shown. A roof substrate, if shown, would appear to the right of shingle 501. Shingle 401 and shingle 501 may each comprise one layer as shown. However, shingles according to some embodiments of the present disclosure may each have one layer or a plurality of layers.
FIG. 4A and FIG. 4B respectively illustrate top and back surfaces of dragon's tooth shingle 601 according to embodiments of the disclosure. As seen in FIG. 4A, some embodiments of the present disclosure may relate to shingles with a dragon's tooth design. Shingle 601 comprises first layer 622 and second layer 624. Shingle 601 in FIG. 4A may comprise buttlap region 604 with top layer 622 and bottom layer 624. In some embodiments, top layer 622 may comprise tabs 618 with substantially trapezoidal geometries (e.g., a dragon's tooth design) and corresponding cut-outs 620. FIG. 4A and FIG. 4B are given by way of example that the present disclosure is not limited to any particular shingle structure, as shingle 601 may comprise headlap region 602 having top headlap surface 606 and back headlap surface 608; and buttlap region 604 having top buttlap surface 610 and back buttlap surface 612. Top headlap surface 606 may comprise sealant 611 and tape 614 positioned along opposite edges. Back headlap surface 608 may comprise tape 616 positioned along the lower edge of 608. Back buttlap surface 612 may comprise sealant 613 positioned along lower edge of shingle 601. As shown in FIG. 4B and FIG. 4C, bottom layer 624 may extend from the lower edge of shingle 601 across buttlap 604 and partially into headlap 602 to a point adjacent to tape 616.
FIG. 4C illustrates a profile view of system 600 according to embodiments of the present disclosure. As shown, system 600 comprises shingles 601 and 601′. Sealant 613 of shingle 601 contacts sealant 611′ in successive shingle 601′ as shown. Tape 616 on back headlap surface 608 contacts tape 614′. The back surface of layer 624 (e.g., surface 612) contacts the top headlap surface of the successive shingle below tape 614′. A roof substrate, if shown, would appear to the right of system 600. Each of a plurality of layers within a shingle may comprise a different material and may be of a different shape, size, or thickness. Variations in these attributes may help achieve aesthetic and/or functional goals such as thinner shingles or lighter shingles, according to some embodiments.
FIG. 5A illustrates a profile view of shingle system 700 according to embodiments of methods for packaging assemblies of shingles according to the disclosure. As seen in FIG. 5A, shingle 701 and shingle 801 may be positioned such that top headlap surface 806 of shingle 801 substantially contacts back buttlap surface 712 of shingle 701. Two shingles 701, 801 may be positioned such that top buttlap surface 810 of shingle 801 substantially contacts back headlap surface 708 of shingle 701. Upper edge 730 of shingle 700 may be adjacent to, may be aligned with, and/or may contact lower edge 831 of shingle 800. Upper edge 830 of shingle 801 may be adjacent to, may be aligned with, and/or may contact lower edge 731 of shingle 701. Pluralities of shingles may be arranged in the above fashion following the described method. Accordingly, pluralities of shingles may be arranged as an assembly that may be convenient for packing and packaging of the shingles. In some embodiments, release tapes may contact one or more of sealant 711, sealant 713, sealant 811, and/or sealant 813 (e.g., sealant 713 and sealant 811).
FIG. 5B illustrates an exploded view of one portion of the profile view of FIG. 5A. As seen in FIG. 5B, shingle 701 and shingle 801 may be positioned such that sealant 713, disposed on back buttlap surface 812, contacts tape 814 on top headlap surface 806. Sealant 713 may comprise material that may not become adhesive until contact or mating with a material of like quality. Accordingly, sealant 713 may not become adhesive when overlapping with tape 814.
FIG. 5C illustrates an exploded view of one portion of the profile view of FIG. 5A. As seen in FIG. 5C, shingle 701 and shingle 801 may be positioned such that sealant 811 on top headlap surface 806 contacts or rests against tape 716 on back headlap surface 708 (adjacent to back buttlap surface 712). Sealant 711 may similarly contact or rest against a tape on a successive shingle (not shown). Tape 816 on back headlap surface 808 (adjacent to back buttlap surface 812) may, in turn, contact a sealant on a successive shingle. Sealant 811 may not become adhesive until contact or mating with a material of like quality (e.g., another conditional sealant). Accordingly, sealant 811 may not become adhesive when contacting tape 716. In some embodiments, sealant 716 may substantially overlap or rest against a top surface of another single.
As seen in FIG. 5A, FIG. 5B, and FIG. 5C, shingles according to embodiments of the present disclosure may each comprise one layer. However, shingles of the present disclosure may also comprise a plurality of layers, and some embodiments may be used in the methods for packaging assembles of shingles according to the present disclosure. For example, FIG. 6A and FIG. 6B illustrate profile views of shingle system 900 wherein shingles 901 and 1001 may comprise a plurality of layers.
FIG. 6 illustrated assembly 900 in which shingles 901 and 1001 are positioned to contact one another substantially without adhering to one another (e.g., for shipping). As seen in FIG. 6, shingle 901 may comprise upper layer 922 and lower layer 924 and shingle 1001 may comprise upper layer 1022 and lower layer 1024. Headlap 902 may comprise oppositely facing top surface 906 and back surface 908. Buttlap 904 may comprise oppositely facing top surface 910 and back surface 912. Buttlap region 904 may comprise a portion of upper layer 922 and a portion of lower layer 924. Similarly, headlap 1002 may comprise oppositely facing top surface 1006 and back surface 1008. Buttlap 1004 may comprise oppositely facing top surface 1010 and back surface 1012. Buttlap region 1004 may comprise a portion of upper layer 1022 and a portion of lower layer 1024. Tape 914 and tape may be affixed adjacent to upper edges 930 and 1030, respectively. Tape 916 may be affixed to headlap surface 908 adjacent to the upper edge of layer 924. Tape 1016 may be affixed to headlap surface 1008 adjacent to the upper edge of layer 1024. Sealant strip 911 and sealant strip 1011 may be affixed to layers 922 and 1022 along the approximate middle of shingles 901 and 1001, respectively. Sealant strip 913 and sealant strip 1013 may be affixed to layers 924 and 1024 adjacent lower edges 931 and 1031, respectively.
Methods of packaging assemblies of shingles according to the present disclosure may comprise positioning shingle 901 and shingle 1001 such that top headlap 1006 abuts back buttlap 912, back headlap 908 abuts top headlap 1010, upper edge 930 of shingle 901 may be adjacent to, may be aligned with, and/or may contact lower edge 1031 of shingle 1001, upper edge 1030 of shingle 1001 may be adjacent to, may be aligned with, and/or may contact lower edge 930 of shingle 901, and/or layer 924 and layer 1024 do not substantially overlap. Sealant 911 and/or sealant 1013 may not become adhesive until contact or mating with another sealant (e.g., each other). Sealant 913 and/or sealant 1011 may not become adhesive until contact or mating with another sealant (e.g., each other). Accordingly, for example, sealant 913 may not become adhesive when contacting tape 1014 on layer 1022 as shown. Sealant 1011 may not become adhesive when contacting tape 916 on layer 922. In some embodiments, assembly 900 may include a third shingle, for example, to the right of shingle 1001. A third shingle may be oriented like shingle 901. By stacking pluralities of shingles according to the presently described method, an assembly of shingles for packaging may be formed.
FIG. 7 illustrates a top view of two shingles aligned according to an embodiment of the disclosure. As shown, shingle system 1100 may comprise shingles 1101, 1201 disposed against one another. In some embodiments, shingle system 1100 may be operable as a roofing system for cladding a structure. In some embodiments, shingle 1101 and shingle 1201 may be positioned such that there may be a vertical offset and a lateral offset relative to each other. For example, shingle 1101, which may be disposed above shingle 1201, may not be aligned such that the length of shingle 1101 may be disposed directly over the length of shingle 1201. Instead, the length of shingle 1101 may be staggered or offset laterally from the length of shingle 1201. As shown here, shingle 1101 is shifted laterally to the left of shingle 1201 such that spacings 1120 are aligned with the middle of tabs 1218. Shingle 1101 is vertically offset such that sealant 1113 (not visible in this view) on the back of tabs 1118 aligns with and contacts sealant 1211. In some embodiments, pluralities of shingles may be arranged in the presently described staggered fashion as part of a roofing system on a structure. A staggered arrangement or lateral offset between shingles may advantageously promote stability between shingles of a roofing system and may serve to promote various other aesthetical or functional objectives.
As will be understood by those skilled in the art who have the benefit of the instant disclosure, other equivalent or alternative articles, systems, and methods for shingles with dual sealants may be envisioned without departing from the description contained herein. Accordingly, the manner of carrying out the disclosure as shown and described is to be construed as illustrative only.
One of ordinary skill in the art having the benefit of the present disclosure may make various changes in the shape, size, number, materials, and/or arrangement of parts without departing from the scope of the instant disclosure. For example, the position and number of sealants or plurality of areas of sealants may be varied. In addition, the size of the articles and/or systems may be scaled up or down to suit the needs of a particular use or roofing structure. Each disclosed method and method step may be performed in association with any other disclosed method or method step and in any order according to some embodiments. Where the verb “may” appears, it is intended to convey an optional and/or permissive condition, but its use is not intended to suggest any lack of operability unless otherwise indicated. One of ordinary skill in the art having the benefit of the present disclosure may make various changes in methods of use and methods of manufacturing the articles and/or systems of the disclosure.
Also, where ranges have been provided, the disclosed endpoints may be treated as exact and/or approximations as desired or demanded by the particular embodiment. Where the endpoints are approximate, the degree of flexibility may vary in proportion to the order of magnitude of the range. For example, on one hand, a range endpoint of about 50 in the context of a range of about 5 to about 50 may include 50.5, but not 52.5 or 55 and, on the other hand, a range endpoint of about 50 in the context of a range of about 0.5 to about 50 may include 55, but not 60 or 75. In addition, it may be desirable, in some embodiments, to mix and match range endpoints. Also, in some embodiments, each figure disclosed (e.g., in one or more of the examples, tables, and/or drawings) may form the basis of a range (e.g., depicted value+/−about 10%, depicted value+/−about 50%, depicted value+/−about 100%) and/or a range endpoint. With respect to the former, a value of 50 depicted in an example, table, and/or drawing may form the basis of a range of, for example, about 45 to about 55, about 25 to about 100, and/or about 0 to about 100.
All or a portion of a device and/or system for articles, systems, and methods for shingles with dual sealants may be configured and arranged to be disposable, serviceable, interchangeable, and/or replaceable. These equivalents and alternatives along with obvious changes and modifications are intended to be included within the scope of the present disclosure. Accordingly, the foregoing disclosure is intended to be illustrative, but not limiting, of the scope of the disclosure as illustrated by the appended claims.
The title, abstract, background, and headings are provided in compliance with regulations and/or for the convenience of the reader. They include no admissions as to the scope and content of prior art and no limitations applicable to all disclosed embodiments.

Claims

1. A shingle comprising:

a headlap region comprising

a top headlap surface having a first conditional sealant, and

a back headlap surface;

a buttlap region comprising

a top buttlap surface, and

a back buttlap surface having a second conditional sealant;

wherein the first conditional sealant and/or the second conditional sealant are each formulated to have substantially no adhesiveness alone, but become adhesive upon contact with the other.

2. A shingle according to claim 1, wherein the first sealant and second sealant have substantially stripe-shaped geometries.

3. A shingle according to claim 1, wherein the first sealant is about 0.2 inches to about 0.6 inches wide, the second sealant is about 0.2 inches to about 0.6 inches wide or the first sealant and the second sealant are each about 0.2 inches to about 0.6 inches wide.

4. A shingle according to claim 1, wherein the first sealant and the second sealant have substantially the same shape and substantially the same size.

5. A shingle according to claim 1, wherein the first sealant extends along a lower edge of the top headlap surface, the second sealant extends along a lower edge of the back buttlap surface, or both the first sealant extends along the lower edge of the top headlap surface and the second sealant extends along the lower edge of the back buttlap surface.

6. A shingle according to claim 1, wherein the first sealant and the second sealant have substantially the same composition.

7. A roofing system for cladding a structure; the roofing system comprising:

a first shingle and a second shingle wherein each shingle comprises

a headlap region comprising

a top headlap surface having a first conditional sealant, and

a back headlap surface;

a buttlap region comprising

a top buttlap surface, and

a back buttlap surface having a second conditional sealant;

wherein the first conditional sealant and the second conditional sealant are each formulated to have substantially no adhesiveness alone, but become adhesive upon contact with the other, and

wherein the first sealant of the first shingle is aligned with and contacts the second sealant of the second shingle.

8. A roofing system according to claim 7 further comprising a third shingle, wherein the second sealant of the first shingle is aligned with and contacts a first sealant of the third shingle.

9. A roofing system according to claim 7, wherein the first sealant and second sealant of each shingle have substantially stripe-shaped geometries.

10. A roofing system according to claim 7, wherein the first sealant and second sealant of each shingle have substantially the same shape and substantially the same size.

11. A roofing system according to claim 7, wherein the first sealant of each shingle is about 0.2 inches to about 0.6 inches wide, the second sealant of each shingle is about 0.2 inches to about 0.6 inches wide or the first sealant and the second sealant of each shingle are about 0.2 inches to about 0.6 inches wide.

12. A roofing system according to claim 7, wherein the first sealant and the second sealant of each shingle have substantially the same composition.

13. A method for cladding a structure comprising a substrate, the method comprising:

providing a first shingle and a second shingle, wherein each shingle comprises

a headlap region comprising

a top headlap surface having a first conditional sealant, and

a back headlap surface,

a buttlap region comprising

a top buttlap surface, and

a back buttlap surface having a second conditional sealant; and

contacting the first sealant of the first shingle and the second sealant of the second shingle,

wherein the first conditional sealant and the second conditional sealant are each formulated to have substantially no adhesiveness alone, but become adhesive upon contact with the other.

14. A method according to claim 13 further comprising providing a third shingle, and contacting the second sealant of the first shingle and a first sealant of the third shingle.

15. A method according to claim 13, wherein the first sealant and second sealant of each shingle have substantially stripe-shaped geometries.

16. A method according to claim 13, wherein the first sealant and second sealant of each shingle have substantially the same shape and substantially the same size.

17. A method according to claim 13, wherein the first sealant of each shingle is about 0.2 inches to about 0.6 inches wide, the second sealant of each shingle is about 0.2 inches to about 0.6 inches wide or the first sealant and the second sealant of each shingle are about 0.2 inches to about 0.6 inches wide.

18. The method according to claim 13, wherein the first sealant and the second sealant of each shingle have substantially the same composition.

19. A method for manufacturing a shingle, the method comprising:

providing a shingle, the shingle comprising

a headlap region comprising a top headlap surface and a back headlap surface, and

a buttlap region comprising a top buttlap surface and a back buttlap surface;

providing a first conditional sealant on the top headlap surface; and

providing a second conditional sealant on the back buttlap surface;

20. The method according to claim 19, wherein the first sealant and second sealant have substantially stripe-shaped geometries.

21. The method according to claim 19, wherein the first sealant and the second sealant have substantially the same shape and substantially the same size.

22. The method according to claim 19, wherein the first sealant is about 0.2 inches to about 0.6 inches wide, the second sealant is about 0.2 inches to about 0.6 inches wide or the first sealant and the second sealant are each about 0.2 inches to about 0.6 inches wide.

23. The method according to claim 19, wherein providing a first conditional sealant on the top headlap surface further comprises providing the first sealant on the top headlap surface along a lower edge of the headlap and providing a second conditional sealant on the back buttlap surface further comprises providing the second conditional sealant on the back buttlap surface along a lower edge of the buttlap.

24. An assembly of shingles, the assembly comprising:

a first shingle and a second shingle wherein each shingle comprises

a headlap region comprising

a top headlap surface having a first conditional sealant, and

a back headlap surface;

a buttlap region comprising

a top buttlap surface, and

a back buttlap surface having a second conditional sealant;

wherein the top headlap surface of the first shingle is substantially aligned with and contacts the back buttlap surface of the second shingle;

wherein the top buttlap surface of the first shingle is substantially aligned with and contacts the back headlap surface of the second shingle;

wherein the first sealant and second sealant of each shingle have substantially stripe-shaped geometries; and

wherein the first sealant of each shingle is about 0.2 inches to about 0.6 inches wide and the second sealant of each shingle is about 0.2 inches to about 0.6 inches wide.

25. A method of packing an assembly of shingles, the method comprising:

providing a first shingle and a second shingle wherein each shingle comprises

a headlap region comprising

a top headlap surface having a first conditional sealant, and

a back headlap surface;

a buttlap region comprising

a top buttlap surface, and

a back buttlap surface having a second conditional sealant;

positioning the top headlap surface of the first shingle to be substantially aligned with and contacting the back buttlap surface of the second shingle;

positioning the top buttlap surface of the first shingle to be substantially aligned with contact the back headlap surface of the second shingle;