US3003288A - Self sealing asphalt shingles - Google Patents

Description

Oct. 10, 1961 w. v. LEIBROOK ETAL 3,

SELF SEALING ASPHALT SHINGLES 2 Sheets-Sheet l 2 Filed June 17, 1957 m m W 1 X y m M a 52024;: Jen/m? 21040;

Oct. 10, 1961 w. v. LEIBROOK ETAL 3,003,238

SELF SEALING ASPHALT samcuas I Filed June 17, 1957 1? Sheets-Sheet 2 IN VEN TORJ.

ATTORNEYS.

United States Patent 3,003,288 SELF SEALING ASPHALT SHINGLES Walton V. Leibrook, Wyoming, and George Arthur Fasold, Mount Healthy, Ohio, assignors to The Philip Carey Manufacturing Company, Cincinnati, Ohio, a

corporation of Ohio Filed June 17, 1957, Ser. No. 665,957 4 Claims. (Cl. 50-403) This invention relates to self sealing shingles provided with sealing elements so positioned that when the shingles are laid the sealing elements hold down the shingles and prevent lifting thereof under high winds and also prevent lifting of the exposed areas of the shingles when the roofs are subjected to low temperatures.

This application is a continuation-in-part of our copending applications, Serial No. 634,708 filed January 17, 1957, now Patent No. 2,863,405, and Serial No. 597,278 filed July 1-1, 1956 now abandoned, which in turn is a continuation-impart of Serial No. 506,796 filed May 9, 1955, now abandoned.

When shingles are laid on a roof in the normal conventional manner, the exposure portions of the shingles of one course are not secured to the underlying unexposed portions of shingles in the next lower course. For this reason, under high wind conditions the exposure areas of the shingles can lift and if the wind conditions are severe enough, severe damage to the roof can result. Furthermore, under the influence of very low temperatures the exposed areas of the shingles have a tendency to lift and again permit winds to further lift the shingles.

In order to overcome the foregoing objections, it has been proposed to provide asphalt shingles with sealing strips which the heat of the sun will soften and adhesively secure the shingle butts to the unexposed portions of the underlying shingles. The success of such so-called self sealing shingles is dependent on the weather and if there is no sunshine for a substantial period the shingles may be blown oil? before the adhesive has a chance to seal. The application to the shingles of a pressure sensitive adhesive material of a tacky nature, such that it will adhere on contact, is a new departure in the shingling art but it introduces a problem in connection with packing and shipment of the shingles. In order for the adhesive portions to be capable of adhering properly in placement on the roof, the adhering surface must be kept clean, so that some sort of protective surface must be provided for in packing and shipment. At the same time, it is necessary to provide for the exposure of the tacky surface for use.

The principal way in which a solution of this problem has been attempted in the past is to provide along the butt edges on the underside of the shingle a strip or patches of adhesive material and then to pack the shingles back to back with the fracturable elements of one shingle engaging the fracturable element of the other shingle, so that a pair of shingles are adhered together. When it is desired to apply theshingles, they must be manually broken apart and it is of course, intended that the break'shall take place in the body of the adhesive material so that some adhesive material will remain on each of the shingles. But still sunshine or solar radiation is required to activate the adhesive. The desired effect is not always and uniformly obtained and furthermore after the shingles are separated, every other shingle must be turned over before it is applied. Thus, the application of shingles of this type is a cumbersome and awkward operation and has not always been successful. The difliculty in the separation of shingles increases with the temperature and the hotter the day, the more difficult it is to separate the shingles. At low temperatures this brittle adhesive shatters when the shingles are broken apart and the small particles may fall on the exposed portions of the shingles and cause discoloration also.

With the foregoing considerations in mind, it is an object of the present invention to provide asphalt shingles with carefully controlled and positioned areas of applied adhesive, which areas may be protected for purposes of packaging and shipment, so that when the protection is removed the adhesively coated areas of the shingles will adhere without heating. Because the adhesive is such that immediate scaling is obtained, it is very important that the adhesive surface be protected during shipment and handling so that when the protection is removed the clean tacky surface is exposed.

Heretofore in self sealing or heat sealing shingles it has always been supposed that the butt edges of the shingles must be securely adhered to underlying courses. The idea of building a roof with the butt edges not adhesively secured by stripes (either intermittent or continuous) of adhesive would have seemed preposterous. It has always been felt that once wind of high velocity gets underneath the shingle butts, wind damage would be bound to result. We have found that the foregoing supposition is without factual basis.

We have found that by purposely positioning stripes of adhesive substantially from two to three inches above the butts on the upper granule surface of the shingles and matching with the line of the top edges of the underlying course of shingles the slight upward bulge of the shingle surfaces or this fulcrum along this line provides a. surprisingly adequate space for attachment even though the two inch lower undersurface of the shingle butts is unsecured in the roof.

The answer to the normal inquiry why a roof with substantially from two to three inches of the butts unsecured does not offer an obvious wind hazard lies in the fact that the spaced adhesive stripes aligned with the bulges caused by the top edges of the underlying courses makes such a firm adhesive attachment that the loose butts are unaffected by wind of high velocity. In actual tests with double coverage roofs laid in accordance With our invention after 48 hours exposure at a temperature of from 70 to 74 F., winds of 50 mph. velocity have no effect. It is an unexpected phenomenon best answered by the statement that while the reason why is difficult to understand, the fact remains that such construction comes closed to hurricane proofness than has heretofore been possible. As one surprising evidence of this wind stability a roof laid in accordance with our invention after 18 hours outside with sunshine withstood a wind velocity of 75 miles per hour which is hurricane velocity, without any wind damage effect.

Our discovery about positioning a band of pressure sensitive adhesive in such position on the'shingles that firm adhesion occurs along the bulge or fulcrum formed by the top edges of the underlying courses of shingles makes it possible to apply the adhesive either to the granule coated upper surface of nonexposed areas'of the shingles or to the bottom'surfacesof the shingles as long as the spacing of the stripes of adhesive is accurately arranged tooverlie the bulges of the top edges of the underneath courses The disclosure of this application will be limited to the shingle construction with the adhesive stripe applied to the upper or granule coated surfaces of the shingles.

It should be understood that, while we have referred to substantially two to three inches, this spacing of the adhesive stripe on a shingle is dependent on how the shingles are to be laid. Strip shingles are elongated substantially rectangular bodies having tab defining slots extending inwardly from the butt edges of the exposure portions of the shingles. In a so-called double coverage arrangemen the shingle elements are laid with others in lapping courses in which the butt edges of one course substantially coincide with the line of the upper inner edges of the tab defining slots of the underlying courses. Shingles for double coverage are normally about two inches in depth more than double the depth of the tab defining slots. As an example, with seven inch tabs the shingle will be sixteen inches in depth, with five inch tabs the shingle will be twelve inches in depth. This means that there is a head lap of about two inches which an underlying course extends under at that part of the combination where there are three thicknesses of shingle. This head lap of underlying courses always forms an upward bulge or fulcrum in each course slightly above the line of the upper edges of the tab defining slots and it is with reference to this head lap line that the stripes of adhesive are positioned.

A further object in the manufacture of the shingles is to control the application of asphalt coating and surfacing materials in certain areas of the shingles to provide nesting grooves on the under surfaces of the shingles so that in packaging for shipment the nesting grooved areas will match with the protruding stripes of pressure sensitive thermoplastic adhesive so that these bands or stripes will not be pressed out fiat during shipment.

Another object is to cover the adhesive strips or stripes with a novel type of tape which not only stays in position but may be readily removed with a slight pull from an exposed edge.

A preferred apparatus and method of applying the adhesive stripes or hands to the shingles is disclosed in our application Serial No. 557,563 filed January 5, 1956, and a method which, with modifications, may be used to apply adhesive in stripes or bands under the butt edges of shingles on a roof laid with regular non-self sealing shingles, is disclosed in our application Serial No. 480,- 747 filed January 10, 1955, now Patent No. 2,871,817.

We propose to explain our invention by reference to its use on 16" x 42.85" strip shingles for double coverage in the drawings and in the explanatory material following. In principle our invention is equally applicable to any shingles wherein a bulge is formed across the surface of the shingle by underlying shingle edges.

Referring to the drawings:

FIGURE 1 is a plan view of a shingle made in accordance with our invention.

FIGURE 2 is a lateral section along the lines 2-2 of FIGURE 1.

FIGURE 3 is a perspective view of a portion of a roof laid in accordance with our invention as shown in FIG- URE 1.

FIGURE 4 is a sectional view taken along the lines 4-4 of FIGURE 3.

FIGURE 5 is a plan view of a modified arrangement in which the use of tape to cover the adhesive stripe is not required.

FIGURE 6 is a lateral sectional view along the lines 6-6 in FIGURE 5. V I

FIGURE 7 is a perspective view of a portion of a roof laid in accordance with the modification shown in FIG- URE 5. V

FIGURE 8 is a sectional view taken along the lin 8-8 in FIGURE 7.

The strip shingle 1 illustrated for a seven inch tab exposure has dimensions of 16" height and a length of 42.85"- The exposure area of such a shingle 1a is seven" inches. The shingles are cut in the usual way from a web three times the width of the shingle for a 48" width machine. For a 7 2" wide machine with 8" shingle tab exposure areas the shingles would be cut from a web four times the width (18") of the shingle.

The shingles consist of a saturated felt web 2 coated on the lower surface with an asphalt coating 3 covered with a layer of sand 3a or other finely divided mineral matter, and with the upper surface also coated with a layer of coating4 surfaced with mineral granules 5.

The shingle is cut with tab defining slots 6 extending from the butt edge 7 of the shingle approximately seven inches. These tab defining slots give the roof the appearance of being laid with single unitary shingles. This is the purpose of strip shingles to greatly simplify the labor involved in laying the roof, and the wider the exposure area, the fewer shingles are required to cover the roof and the expense of laying is materially reduced.

The appearance of a roof laid with seven inch exposure areas particularly in ranch type homes is muchmore satisfying than the appearance of roofslaid with five inch exposure areas in that the monotony of many lateral lines of the butt edges of shingles is avoided.

The method of laying strip shingles of the type illustrated in FIGURES 1 and 2 is best shown in FIGURES 3 and 4. The row of shingles at the eaves is formed by a row of shingles-8 cut off nine inches from the upper portion. Further underneath the 9 inch row there is a two inch strip 9 which forms the first fulcrum for the adhesive stripe of this first course. The remaining courses are made by laying the full size shingles as illustrated in FIGURE 1. It will be noted that each course is laid with butts parallel with the upper edges of the tab defining slots of the underlying course. Since there is a seven inch exposure area there is always a narrow triple coverage zone but the balance of the shingles form only double coverage. 7

Referring to FIGURE 4 it will be observed that the lines 10 of the upper edges of'the' head laps of each course of shingles forms a bulge extending across the roof above the lines of the top edges of the cut-out tab slots.

It is a particular feature of our invention as described herein as applied to seven inch exposure tab assemblies to provide beads or stripes of sealing material '11 substantially two inches above the top edges of the cut-outs. This means the underneath surface of the shingles is unattached in the roof in the two inch strip along the shingle butts.

The shingle nails, as indicated at 12, are inserted above the cut-outs so that they are inserted in the triple coverage area of the shingle assembly.

The pressure sensitive rubber-asphaltic material 11 may conveniently be covered with tape 13 which is pulled off either before or after the shingle is nailed on the roof.

To compensate for the thickness of the strip or stripe of pressure sensitive self-sealing adhesive, the shingles during manufacture have nesting grooves 14- ex-actly opposite the line on which the self-sealing adhesive stripe is to be applied so that in packaging the shingles the adhesive stripe will not be subjected to pressure which would otherwise squeeze out the stripe. The position of the'shingles in packaging is indicated in dotted lines in FIGURE 2.

Referring now to FIGURES 5 to 8 it will be obvious that as far as the shingles are concerned the construction is the same. The strip shingles 1 have a tab exposure area 1a. The saturated web 2 is coated on the lower surface with an asphalt coating 3 covered with a layer of sand 3a or other backing material. The upper surface is formed with a coating 4 ofasphaltic material covered with granules 5.

The tab defining slots 6 extending in from the butt edges 7 provide an exposure area of seven inches. As stated, this exposure area may be five, eight or teninches depending on the size and cutting of the shingle units.

The course of shingles 8 atthe caves are cut off to nine inches in depth and a strip 9 has an upper edge which provides the fulcrum along the line of which the nine inch course is secured. Also there is provided a drip edge which supports the lower edges of the 9 inch course.

Referring to FIGURE 8, the lines 10 of the upper edges of the head laps of each course of shingles form a bulge or fulcrum line across the roof above the lines of the top edges of the cut-out tab slots.

The strips or stripes of pressure sensitive adhesive 11 are substantially two inches above the top edges of the tab cut-outs. The underneath surface of the shingles is unattached in the roof for about two inches extending up underneath the shingle butts.

The shingle nails as indicated at 12 are inserted above the cut-outs so that they are inserted in the triple coverage area of the shingle assembly.

In the modification illustrated in FIGURES 5 to 8, the adhesive stripes are uncovered, the tape 13a being inserted at the bottom of the nesting grooves 14. There is no adhesion of the shingles one to another in the shingle packages since the tape is repellant to adhesion.

In laying the shingles of the modification shown in FIGURES 5 to 8, there is no necessity for removing the tape 13a since it will all be covered by overlying courses of shingles. In some instances instead of a tape 13a secured at the bottoms of the nesting grooves, the bottoms of the nesting grooves may be coated with adhesive repellant solution which on drying will have the same adhesion negating effect as the tape.

Summarizing the advantages of our invention in its several modifications, we have changed the location of the adhesive line. (The line is higher than formerly and permits nailing below the adhesive line but above the cut-outs). The natural contour of the shingles as they are applied provides for immediate contact with the adhesive line, in its new location, thus a quicker seal is obtained. A solid line of adhesive is applied. With the narrow cut-outs A" and the tight seal obtained with the new solid adhesive line, the amount of wind-driven rain that may get behind the shingle tabs is negligible.

A wider and thicker band of adhesive is applied. Actually more than four times as much adhesive is applied to our improved shingle than has previously been applied. An immediate pressure seal is obtained and there is no need to wait and hope for the heat of the sun to provide the initial seal.

A new type wider strippable tape has been provided. A protective nest is provided for adhesive and tape while packaged. An ingenious feature built into the back of each shingle permits storage in warehouse stocks and prevents flattening out of the adhesive due to pressure. We have a sealant that is far more eifective than that used by others. This is easily and efiectively demonstrated-one can simply take two tabs of our shingle, remove the tape from one tab and press them together with the finger tips in the position they would be when applied. The adhesive is so tenacious that both tabs may be picked up and holding by the top of the top shingle they will stick together when held perpendicular. Our pressure sensitive thermoplastic adhesive is more adhesive. By comparison a brittle, thermoplastic, depending solely on the heat of the sun to accomplish scaling, is not nearly so effective. Our improved shingles applied to decks without any pressure and aged in a room 70-74" F. after 48 hours will pass a 50 mile per hour wind test without any of the tabs blowing up. When applied to a deck outdoors for 48 hours-with prevailing air temperature between 32 and 63 F. and having four to five hours sun on them, our new shingles passed a 75 mile an hour wind test. In other words, they will withstand hurricane velocity.

Having thus described our invention, What we claim as new and desire to secure by Letters Patent is:

1. A high wind resistant roof covering comprising a plurality of similar flexible shingles laid in a double coverage arrangement, wherein the most underlying shingle has a head lap of not less than two inches, so that in the head lap area, portions of three shingles are superposed upon each other, and wherein the top edge of said head lap forms an upwardly bulging fulcrum in the surface of the intermediate shingle in said area, each of the similar shingles in said double coverage arrangement comprising a substantially rectangular body and having a substantially thick stripe of pressure sensitive adhesive of a tacky nature extending thereacross in alignment with the upwardly bulging :fiulcrum formed by the top edge of the head lap of the most underlying shingle, and in the unexposed area of said shingle, whereby said stripe of adhesive is disposed between the uppermost and intermediate shingle in said head lap area.

2. A roof covering according to claim 1, wherein said stripe is on the upper surface of the shingle, and wherein each shingle has a nesting groove on its undersurface in alignment with said stripe.

3. A high wind resistant roof covering comprising a plurality of similar flexible shingles laid in a double coverage arrangement, wherein the most underlying shingle has a head lap of not less than two inches, so that in the head lap area, portions of three shingles superimposed upon each other, and wherein the top edge of said head lap forms an upwardly bulging fulmum in the surface of the intermediate shingle in said area, each of the similar shingles in said double coverage arrangement comprising a substantially rectangular body having tab defining slots extending up from its lower edge, the double coverage arrangement further being such that each shingle is laid with other similar shingles so that its lower edge substantially coincides with the line of the top edges of the tab defining slots of an underlying shingle, each said shingle having a substantially thick stripe of pressure sensitive adhesive of a tacky nature extending thereacross in alignment with the upwardly fulcrum formed by the top edge of the head lap of the most underlying shingle, and in the unexposed area of said shingle, whereby said stripe of adhesive is disposed between the uppermost and intermediate shingle in said head lap area.

4. A roof covering according to claim 3, wherein said stripe is on the upper surface of the shingle, and wherein each shingle has a nesting groove on its undersurface in alignment with said stripe.

References Cited in the file of this patent UNITED STATES PATENTS 1,376,215 Millard Apr. 26, 1921 1,498,947 Bewan June 24, 1924 1,552,883 Rudel Sept. 8, 1925 1,568,227 Leonard Jan. 5, 1926 1,881,438 Fischer Oct. 11, 1932 1,925,961 Harshberger Sept. 5, 1933 2,048,663 Miller July 21, 1936 2,210,209 Kirschbraum Aug. 6, 1940 2,222,868 Hollister Nov. 26, 1940 2,300,488 C-uno Nov. 3, 1942 2,387,593 Lesser Oct. 23, 1945 2,552,159 Eason May 8, 1951 2,565,509 Marcin Aug. 28, 1951 2,667,131 Clarvoe Jan. 26, 1954 2,822,085 Bettoli Feb. 4, 1958 2,863,405 Leibrook Dec. 9, 1958 2,935,416 Dunbar May 3, 1960

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