Granted Patent B2

US 8,615,968 · App. 13/855,820 · Granted Dec 31, 2013

Inventors: Husnu M. Kalkanoglu (Swarthmore, PA); Stephen A. Koch (Collegeville, PA)

Assignee: CertainTeed Corporation

Abstract

Claims (45)

1. An array of shingles applied to a roof, by fasteners, in courses, each shingle having front and rear exterior surfaces and being comprised of shingle material, with the shingle having a width defined by upper and lower edges and a length defined by right and left edges, the shingle comprising:

(a) a base layer of mat having front and rear surfaces;

(b) a coating of asphaltic material on both front and rear surfaces of the mat;

(c) coatings of granular material on said both front and rear surfaces of the mat, which, together with said base layer of mat and said coating of asphaltic material comprise a first thickness layer;

(d) a longitudinal fastening zone between right and left shingle edges, generally intermediate said upper and lower edges;

(e) and an at least partially externally visible generally longitudinal reinforcement second thickness layer of a substantially thinner dimension than said first thickness layer; said reinforcement second thickness layer being adhered to an exterior surface of said shingle and extending at least substantially between right and left edges of the shingle; and

(f) said reinforcement second thickness layer extending at least partially lower than the fastening zone, toward the lower edge of the shingle or at least partially into the fastening zone toward the upper edge of the shingle.

2. The array of shingles applied to a roof according to claim 1 , wherein each shingle is comprised of a single layer of shingle material with the front and rear surfaces being on opposite sides of the single layer of shingle material.

3. The array of shingles applied to a roof according to claim 1 , wherein each shingle is comprised of at least two layers of shingle material laminated together, with the front and rear surfaces being on opposite sides of the single.

4. The array of shingles applied to a roof according to claim 3 , wherein the reinforcement second thickness layer extends at least partially lower than the fastening zone, toward the lower edge of the shingle.

5. The array of shingles applied to a roof according to claim 3 , wherein the reinforcement second thickness layer extends at least partially into the fastening zone, toward the upper edge of the shingle.

6. The array of shingles applied to a roof according to claim 1 , wherein the reinforcement second thickness layer comprises a material selected from the group consisting of woven or non-woven:

(i) thin fabric;

(ii) plastic film;

(iii) paper;

(iv) parchment;

(v) foil; and

(vi) scrim.

7. The array of shingles applied to a roof according to claim 1 , wherein the reinforcement second thickness layer comprises means for increasing resistance to nail pull prior to failure.

8. The array of shingles applied to a roof according to claim 1 , wherein the reinforcement second thickness layer extends at least partially lower than the fastening zone, toward the lower edge of the shingle.

9. The array of shingles applied to a roof according to claim 1 , wherein reinforcement second thickness layer extends at least partially into the fastening zone, toward the upper edge of the shingle.

10. The array of shingles applied to a roof according to claim 9 , including fasteners applied through the reinforcement second thickness layer, fastening the shingles to the roof.

11. A method of applying an array of shingles to a roof, by fasteners, in courses, comprising the steps making a shingle having front and rear exterior surfaces and being comprised of shingle material, with the shingle having a width defined by upper and lower edges and a length defined by right and left edges, comprising the further steps of:

(a) providing a base layer of mat having front and rear surfaces;

(b) providing a coating of asphaltic material on both said front and rear surfaces of the mat;

(c) providing coatings of granular material on the asphaltic material on said both front and rear surfaces, so that the structures of clauses (a), (b) and (c) comprise a first thickness layer;

(d) providing a longitudinal fastening zone between right and left shingle edges, generally intermediate said upper and lower shingle edges;

(e) providing an at least partially externally visible generally longitudinal reinforcement second thickness layer of a substantially thinner dimension than said first thickness layer; and adhering the reinforcement second thickness layer to an exterior surface of the shingle, extending at least substantially between right and left edges of the shingle;

(f) making the reinforcement second thickness layer extend at least partially lower than the fastening zone or at least partially into the fastening zone; and

(g) fastening the shingles to a roof, in courses.

12. The method of claim 11 , wherein each shingle is comprised of a single layer of shingle material, with the front and rear surfaces being on opposite sides of the single layer of shingle material.

13. The method of claim 11 , wherein each shingle is comprised of a at least two layers of shingle material, including the step of laminating the at least two layers of shingle material together, with the front and rear surfaces of the shingle being on opposite sides of the shingle.

14. The method of claim 11 , including the step of extending the reinforcement second thickness layer of each shingle at least partially lower than the fastening zone, toward the lower edge of the shingle.

15. The method of claim 11 , including the step of extending the reinforcement second thickness layer of each shingle at least partially into the fastening zone, toward the upper edge of the shingle.

16. The method of claim 15 , including the step of applying fasteners through the reinforcement second thickness layers of the shingles, fastening the shingles to the roof.

17. A shingle having front and rear exterior surfaces and being comprised of shingle material, with the shingle having a width defined by upper and lower edges and a length defined by right and left edges, the shingle comprising:

(a) a base layer of mat having front and rear surfaces;

(b) a coating of asphaltic material on both front and rear surfaces of the mat;

(c) coatings of granular material on said both front and rear surfaces of the mat, which, together with said base layer of mat and said coating of asphaltic material comprise a first thickness layer;

(d) a longitudinal fastening zone between right and left shingle edges, generally intermediate said upper and lower edges;

(e) and an at least partially externally visible generally longitudinal reinforcement second thickness layer of a substantially thinner dimension than said first thickness layer; said reinforcement second thickness layer being adhered to an exterior surface of said shingle and extending at least substantially between right and left edges of the shingle;

(f) said reinforcement second thickness layer extending at least partially lower than the fastening zone, toward the lower edge of the shingle or at least partially into the fastening zone toward the upper edge of the shingle;

(g) wherein each shingle is comprised of at least two layers of shingle material laminated together, with the front and rear surfaces being on opposite sides of the shingle; and

(h) wherein the at least two layers of shingle material comprise a top sheet and a backing sheet, with the top sheet including a plurality of alternating tabs and cut out portions along a lower longitudinal edge of the top sheet, with portions of the backing sheet being visible through the cutout portions being defined by edges of the tabs and with the cutout portions being of a plurality of longitudinal dimensions.

18. An array of shingles according to claim 17 , applied to a roof, in courses.

Continuity (8)