Enhanced multi-layered shingle
View Patent ↗A multi-layered roofing shingle is described. The layers of the shingle are connected via a mechanical fastener. A method for manufacturing a multi-layered shingle is also described. The method includes aligning the layers of the shingle, and connecting the layers via at least one mechanical fastener. Further described is a multi-layered shingle having layers that are mechanically fastened by deforming one of the layers into one of the other layers.
1. A composition roofing shingle, comprising:
a first layer having an interior surface and an exterior surface, the exterior surface of the first layer providing an initial portion of an exterior of the shingle;
a second layer having an interior surface and an exterior surface, a first portion of the exterior surface of the second layer providing a remaining portion of the exterior of the shingle, and a second portion of the exterior surface of the second layer being adhesively connected to the interior surface of the first layer; and
at least one mechanical fastener disposed into a common bond area between headlap and buttlap portions of the shingle and providing a region for interconnecting the interior surface of the first layer with the exterior surface of the second layer, the at least one mechanical fastener terminating within at least one of the first and second layers such that it is not exposed on the external surface of the first layer.
2. The roofing shingle of claim 1 wherein the first layer includes a first leading edge and the second layer includes a second leading edge, the first and second leading edges being aligned to be substantially flush.
3. The roofing shingle of claim 2 wherein the first layer includes a first trailing edge spaced from and substantially parallel with the first leading edge and the second layer includes a second trailing edge spaced from and substantially parallel with the second leading edge, wherein the distance defined between the first leading edge and the first trailing edge is greater than the distance defined between the second leading edge and the second trailing edge.
4. The roofing shingle of claim 3 wherein the first layer comprises a head portion integrally formed with a tab portion, the tab portion being adhesively connected to the second layer to define a first adhesive connection.
5. The roofing shingle of claim 4 wherein the head portion is adhesively connected to the second layer adjacent to the second trailing edge to define a second adhesive connection.
6. The roofing shingle of claim 5 wherein the at least one mechanical fastener is disposed through a portion of the shingle generally corresponding to the second adhesive connection.
7. The roofing shingle of claim 6 wherein the at least one mechanical fastener is a staple oriented substantially parallel with the second trailing edge.
8. The roofing shingle of claim 6 wherein the at least one mechanical fastener is a staple oriented substantially perpendicular with the second trailing edge.
9. The roofing shingle of claim 6 wherein the at least one mechanical fastener is a staple oriented substantially oblique with the second trailing edge.
10. The roofing shingle of claim 1 wherein the at least one mechanical fastener is selected from the group consisting of a staple, a caltrop, a barbed cleat, a stitching, and a molten fastener.
11. The roofing shingle of claim 1 wherein the at least one mechanical fastener comprises two or more mechanical fasteners, and wherein one of the two or more mechanical fasteners terminates within the first layer and wherein the other of the two or more mechanical fasteners terminates within the second layer.
12. The roofing shingle of claim 1 , further comprising a bituminous coating on the exterior surface of the first layer.
13. The roofing shingle of claim 1 wherein the at least one mechanical fastener extends through the second layer and terminates within the first layer.
14. The roofing shingle of claim 1 , where the first and second layers comprise composition layers.
15. The roofing shingle of claim 14 , where the first and second layers each comprise a fiberglass mat.
16. A roofing shingle comprising:
a first layer having an interior surface and an exterior surface, the exterior surface of the first layer providing an initial portion of an exterior of the shingle; and
a second layer having an interior surface and an exterior surface, a first portion of the exterior surface of the second layer providing a remaining portion of the exterior of the shingle, and a second portion of the exterior surface of the second layer being connected to the interior surface of the first layer via at least one mechanical fastener disposed through a common bond area between headlap and buttlap portions of the shingle and providing a region for interconnecting the interior surface of the first layer with the exterior surface of the second layer, the at least one mechanical fastener terminating within at least one of the first and second layers such that it is not exposed from on the external surface of the first layer.
17. The roofing shingle of claim 16 wherein the mechanical fastener is selected from the group consisting of a staple, a caltrop, a barbed cleat, a stitching, and a molten fastener.
18. The roofing shingle of claim 16 wherein the first layer includes a first leading edge and the second layer includes a second leading edge, the first and second leading edges being aligned to be substantially flush.
19. The roofing shingle of claim 18 wherein the first layer includes a first trailing edge spaced from and substantially parallel with the first leading edge and the second layer includes a second trailing edge spaced from and substantially parallel with the second leading edge, wherein the distance defined between the first leading edge and the first trailing edge is greater than the distance defined between the second leading edge and the second trailing edge.
20. The roofing shingle of claim 19 wherein the first layer comprises a head portion integrally formed with a tab portion, the tab portion being adhesively connected to the second layer to define a first adhesive connection.
21. The roofing shingle of claim 19 wherein the at least one mechanical fastener is a staple oriented substantially perpendicular with the second trailing edge.
22. The roofing shingle of claim 19 wherein the at least one mechanical fastener is a staple oriented substantially oblique with the second trailing edge.
23. The roofing shingle of claim 16 further comprising a bituminous coating on the exterior surfaces of the first and second layers.
24. The roofing shingle of claim 16 , where the first and second layers comprise composition layers.
25. The roofing shingle of claim 24 , where the first and second layers each comprise a fiberglass mat.
26. A composition roofing shingle comprising:
a first composition layer having an interior surface and an exterior surface, the exterior surface of the first layer providing an initial portion of an exterior of the shingle; and
a second composition layer having an interior surface and an exterior surface, a first portion of the exterior surface of the second layer providing a remaining portion of the exterior of the shingle, and a second portion of the exterior surface of the second layer being connected to at least a portion of the interior surface of the first layer such that at least a portion of the external surface of the second layer is visible with at least a portion of the external surface of the first layer from an external side of the shingle adapted for exposure to the environment;
at least one mechanical fastener connecting the first and second layers at a common bond area between headlap and buttlap portions of the shingle and providing a region for interconnecting the first and second layers, the at least one mechanical fastener terminating within at least one of the first and second layers such that it is not exposed on the external surface of the first layer;
a bituminous coating disposed on the exterior surfaces of the first and second layers; and
granules disposed on the bituminous coating on the external surfaces of the first and second layers.
27. The composition roofing shingle of claim 26 wherein the first layer includes a first leading edge and the second layer includes a second leading edge, the first and second leading edges being aligned to be substantially flush.
28. The composition roofing shingle of claim 27 wherein the first layer includes a first trailing edge spaced from and substantially parallel with the first leading edge and the second layer includes a second trailing edge spaced from and substantially parallel with the second leading edge, wherein the distance defined between the first leading edge and the first trailing edge is greater than the distance defined between the second leading edge and the second trailing edge.
29. The composition roofing shingle of claim 28 wherein the first layer comprises a head portion integrally formed with a tab portion, the tab portion being adhesively connected to the second layer to define a first adhesive connection.
30. The composition roofing shingle of claim 29 wherein the head portion is adhesively connected to the second layer adjacent to the second trailing edge to define a second adhesive connection.
31. The composition roofing shingle of claim 30 wherein the at least one mechanical fastener is disposed through a portion of the shingle generally corresponding to the second adhesive connection.
32. The composition roofing shingle of claim 31 wherein the at least one mechanical fastener is a staple oriented substantially parallel with the second trailing edge.
33. The composition roofing shingle of claim 31 wherein the at least one mechanical fastener is a staple oriented substantially perpendicular with the second trailing edge.
34. The composition roofing shingle of claim 31 wherein the at least one mechanical fastener is a staple oriented substantially oblique with the second trailing edge.
35. The composition roofing shingle of claim 26 wherein the at least one mechanical fastener is selected from the group consisting of a staple, a caltrop, a barbed cleat, a stitching, and a molten fastener.
36. The composition roofing shingle of claim 26 wherein the at least one mechanical fastener extends through the second layer and terminates within the first layer.
37. The composition roofing shingle of claim 26 , wherein the first and second layers each comprise a fiberglass mat.