Light weight shingle
View Patent ↗The present disclosure relates, according to some embodiments, to articles, systems, and methods for roofing a structure including, for example, layered shingles comprising a plurality of layers. A layered shingle may comprise, in some embodiments, an upper layer and a backing layer comprising a low density aggregate, wherein the backing layer is fixed to the substrate-facing surface of the upper layer.
1. A layered shingle for cladding a structure comprising a substrate, the layered shingle comprising:
an upper layer comprising a substrate-facing surface, the upper layer selected from an asphalt layer, a lamination layer, a paint layer, and a sand or fines layer; and
a backing layer comprising between about 40% to about 90% by weight of expanded clay,
wherein the backing layer is fixed to the substrate-facing surface of the upper layer, and
wherein the upper layer comprises an upper headlap and an upper buttlap, and wherein the upper buttlap comprises two or more tabs interspersed with inter-tab spacings.
2. A layered shingle according to claim 1 , wherein the backing layer further comprises a low density aggregate that is selected from the group consisting of: perlite, polymeric expanded beads, microspheres, expanded graphite, granulated polymers, foamed glass, or combinations thereof.
3. A layered shingle according to claim 1 , wherein the layered shingle is ˜2% to 20% lighter in weight than a corresponding shingle having substantially the same thickness except having a backer comprising sand and/or granule/rock fines.
4. A roofing system for cladding a structure comprising a substrate and an underlayment affixed thereon, the roofing system comprising:
at least one layered shingle comprising:
an upper layer comprising a substrate-facing surface, the upper layer selected from an asphalt layer, a lamination layer, and a paint layer; and
a backing layer comprising between about 40% to about 90% by weight of expanded clay,
wherein the backing layer is fixed to the substrate-facing surface of the upper layer, and
wherein the upper layer comprises an upper headlap and an upper buttlap, and wherein the upper buttlap comprises two or more tabs interspersed with inter-tab spacings.
5. A roofing system according to claim 4 , wherein the backing layer further comprises a low density aggregate that is selected from the group consisting of: perlite, polymeric expanded beads, microspheres, expanded graphite, granulated polymers, foamed glass, or combinations thereof.
6. A roofing system according to claim 4 , wherein the layered shingle is lighter in weight than a corresponding shingle having substantially the same thickness except having a backer comprising sand and/or granule/rock fines.
7. A method for cladding a structure comprising a substrate, the method comprising:
securing a plurality of shingles to the substrate, wherein at least one of the shingles is a layered shingle comprising
an upper layer comprising a substrate-facing surface, the upper layer selected from an asphalt layer, a lamination layer, and a paint layer; and
a backing layer comprising between about 40% to about 90% by weight of expanded clay,
wherein the backing layer is fixed to the substrate-facing surface of the upper layer, and
wherein the upper layer comprises an upper headlap and an upper buttlap, and wherein the upper buttlap comprises two or more tabs interspersed with inter-tab spacings.
8. A method according to claim 7 , wherein the backing layer further comprises a low density aggregate that is selected from the group consisting of: perlite, polymeric expanded beads, microspheres, expanded graphite, granulated polymers, foamed glass, or combinations thereof.
9. A method according to claim 7 , wherein the layered shingle is lighter in weight than a corresponding shingle having substantially the same thickness except having a backer comprising sand and/or granule/rock fines.