Shingle with abraded nail line

Abstract

A roofing shingle includes a visible region for guiding an installer on proper placement of fasteners that secure the shingle to a surface. The visible region is formed by abrading material from the shingle.

Claims

1. A laminated roofing shingle comprising: an underlay sheet; and an overlay sheet bonded to the underlay sheet, wherein the overlay sheet includes a headlap portion and a tab portion, wherein the tab portion comprises a plurality of tabs and a plurality of cutouts, wherein the headlap portion includes an abraded region corresponding to at least a portion of a nail zone of the shingle.

2. The laminated roofing shingle of claim 1, further comprising first granules disposed in the headlap portion, and wherein the first granules in the abraded region of the headlap portion have been modified relative to the first granules outside of the abraded region.

3. The laminated roofing shingle of claim 2, further comprising second granules disposed in the tab portion.

4. The laminated roofing shingle of claim 1, wherein the shingle has a rectangular profile that extends from a first side to a second side and between a top side and a bottom side to define an upper face and a lower face.

5. The laminated roofing shingle of claim 4, wherein the shingle has a first width measured from the top side to the bottom side, wherein the nail zone has a second width, and wherein the second width is smaller than the first width.

6. The laminated roofing shingle of claim 5, wherein the abraded region has a third width, and wherein the second width equals the third width.

7. The laminated roofing shingle of claim 5, wherein the abraded region has a third width, and wherein the second width is greater than the third width.

8. The laminated roofing shingle of claim 4, wherein the shingle has a first length measured from the first side to the second side, wherein the nail zone has a second length, and wherein the first length equals the second length.

9. The laminated roofing shingle of claim 8, wherein the abraded region has a third length, and wherein the third length equals the second length.

10. The laminated roofing shingle of claim 8, wherein the abraded region has a third length, and wherein the third length is less than the second length.

11. The laminated roofing shingle of claim 8, wherein the abraded region includes a plurality of abraded segments, each of the segments having a fourth length, and wherein the second length is at least four times larger than the fourth length.

12. The laminated roofing shingle of claim 8, wherein the abraded region includes a plurality of abraded segments, each of the segments having a fourth length, and wherein the second length is at least ten times larger than the fourth length.

13. The laminated roofing shingle of claim 5, wherein the abraded region comprises a first abraded region and a second abraded region, wherein the first abraded region and the second abraded region are parallel to one another, wherein the first abraded region is closer to the top side than the bottom side, wherein the second abraded region is closer to the bottom side than the top side, wherein a gap separates the first abraded region and the second abraded region, wherein the first abraded region has a third width, wherein the second abraded region has a fourth width, and wherein the gap has a fifth width.

14. The laminated roofing shingle of claim 13, wherein the third width equals the fourth width.

15. The laminated roofing shingle of claim 13, wherein the fifth width is greater than the sum of the third width and the fourth width.

16. The laminated roofing shingle of claim 13, wherein the second width equals the sum of the third width, the fourth width, and the fifth width.

17. The laminated roofing shingle of claim 13, wherein the second width is greater than the sum of the third width, the fourth width, and the fifth width.

18. A method of forming a laminated roofing shingle, the method comprising: providing an underlay sheet; providing an overlay sheet having a headlap portion and a tab portion; depositing a plurality of first granules on the headlap portion; depositing a plurality of second granules on the tab portion; adhering the overlay sheet to the underlay sheet; and removing at least a portion of a surface coating from at least a portion of the first granules to form an abraded region, wherein the abraded region visibly indicates a nail zone of the shingle.

19. The method of claim 18, wherein the abraded region is one of a continuous line extending a length of the shingle and a discontinuous line comprising a plurality of abraded segments.

20. The method of claim 18, wherein the abraded region comprises a first abraded line and a second abraded line separated by a gap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

(2) FIG. 1 is a perspective view of a conventional laminated shingle using a reinforcement member as indicia for a nail zone of the shingle.

(3) FIG. 2 is a top plan view of a conventional laminated shingle using a painted line as indicia for a nail zone of the shingle.

(4) FIG. 3 is a top plan view of a laminated shingle with a continuous abraded line as indicia for a nail zone of the shingle, according to an exemplary embodiment.

(5) FIG. 4 is a top plan view of a laminated shingle with a discontinuous abraded line as indicia for a nail zone of the shingle, according to an exemplary embodiment.

(6) FIG. 5 is a top plan view of a laminated shingle with an abraded line having different textures as indicia for a nail zone of the shingle, according to an exemplary embodiment.

(7) FIG. 6 is a top plan view of a laminated shingle with a pair of continuous abraded lines as indicia for a nail zone of the shingle, according to an exemplary embodiment.

DETAILED DESCRIPTION

(8) Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

(9) The general inventive concepts encompass shingles that are physically altered to produce nail zone indicia thereon. More specifically, a surface coating of granules on a shingle is at least partially removed (e.g., via abrasion) to create indicia for a nail zone of the shingle.

(10) A laminated roofing shingle 300, according to one exemplary embodiment, is shown in FIG. 3. The shingle 300 can have a construction similar to the shingles 100, 200.

(11) The shingle 300 has a rectangular profile that extends from a first side 302 to a second side 304 and between a top side 306 and a bottom side 308 to define an upper face 310 and a lower face (not shown). The shingle 300 includes an overlay sheet 312 attached to an underlay sheet 314. The overlay sheet 312 includes a headlap portion 316 and a tab portion 318. The tab portion 318 defines a plurality of tabs 322 and cutouts 324 between adjacent tabs 322. The headlap portion 316 and the tabs 322 may include one or more granule patterns 326 thereon.

(12) As shown in FIG. 3, the shingle 300 includes a nail zone 330. The nail zone 330 typically overlaps a common bond portion of the shingle 300, where the sheets 312, 314 overlap. The nail zone 330 typically extends a length of the shingle 300 from the first side 302 to the second side 304. The nail zone 330 has a width w.sub.1, situated between the top side 306 and the bottom side 308. The nail zone 330 helps an installer visibly identify the portion of the shingle 300 through which fasteners (e.g., nails) should be installed to anchor the shingle 300 to a roof deck.

(13) To aid in identification of the nail zone 330, the shingle 300 is modified so that the nail zone 330 has a different appearance than other portions of the shingle 300. In particular, the shingle is abraded to form a line 332 within the nail zone 330. The line 332 typically extends a length of the shingle 300 from the first side 302 to the second side 304. The line 332 has a width w.sub.2, situated between the top side 306 and the bottom side 308. In some exemplary embodiments, the line 332 is continuous, as shown in FIG. 3. In some exemplary embodiments, the line 332 is discontinuous, as shown in FIG. 4.

(14) The shingle 300 can be abraded in any manner suitable to remove a portion of the shingle 300 (e.g., at least a portion of the surface coating of granules within the nail zone 330). For example, a moving disk, wheel, belt, or the like with an abrasive surface can be used to form the line 332 within the nail zone 330. The abraded portion of the shingle 300 (i.e., the line 332) will have a different appearance than those adjacent portions of the shingle 300 that are unabraded. Consequently, the line 332 represents a form of nail zone indicia that can be readily and consistently applied to the shingle 300, without requiring application of any additional material (e.g., paint) or component (e.g., reinforcing tape).

(15) Additionally, in some exemplary embodiments, the abraded portion of the line 332 can have a different texture 332a than a texture 332b of those adjacent portions of the line 332 that are unabraded, thereby providing a tactile indication of the nail zone 330 and/or indication of areas in the nail zone 330 representing particularly suitable positions for placements of fasteners, as shown in FIG. 5. One manner of imparting the different textures 332a, 332b could involve the depth of abrasion of the respective regions of the line 332.

(16) In some exemplary embodiments, the width w.sub.2 is greater than ⅛ inch. In some exemplary embodiments, the width w.sub.2 is equal to the width w.sub.1. In some exemplary embodiments, the width w.sub.2 is at least ½ of the width w.sub.1.

(17) Preferably, but not necessarily, the abrasion process occurs in-line during production of the shingle 300.

(18) A laminated roofing shingle 600, according to one exemplary embodiment, is shown in FIG. 6. The shingle 600 can have a construction similar to the shingles 100, 200.

(19) The shingle 600 has a rectangular profile that extends from a first side 602 to a second side 604 and between a top side 606 and a bottom side 608 to define an upper face 610 and a lower face (not shown). The shingle 600 includes an overlay sheet 612 attached to an underlay sheet 614. The overlay sheet 612 includes a headlap portion 616 and a tab portion 618. The tab portion 618 defines a plurality of tabs 622 and cutouts 624 between adjacent tabs 622. The headlap portion 616 and the tabs 622 may include one or more granule patterns 626 thereon.

(20) As shown in FIG. 6, the shingle 600 includes a nail zone 630. The nail zone 630 typically overlaps a common bond portion of the shingle 600, where the sheets 612, 614 overlap. The nail zone 630 typically extends a length of the shingle 600 from the first side 602 to the second side 604. The nail zone 630 has a width w.sub.1, situated between the top side 606 and the bottom side 608. The nail zone 630 helps an installer visibly identify the portion of the shingle 600 through which fasteners (e.g., nails) should be installed to anchor the shingle 600 to a roof deck.

(21) To aid in identification of the nail zone 630, the shingle 600 is modified so that the nail zone 630 has a different appearance than other portions of the shingle 600. In particular, the shingle is abraded to form a first line 636 and a second line 638 within or directly abutting the nail zone 630. The lines 636, 638 typically extend a length of the shingle 600 from the first side 602 to the second side 604. The lines 636, 638 are substantially parallel to one another. The first line 636 has a width w.sub.2, situated between the top side 606 and the bottom side 608. The second line 638 has a width w.sub.3, situated between the top side 606 and the bottom side 608. The space between the lines 636, 638 has a width w.sub.4, as shown in FIG. 6. The first line 636 is closer to the top side 606 than the bottom side 608. The second line 638 is closer to the bottom side 608 than the top side 606. In some exemplary embodiments, one or more of the lines 636, 638 are continuous, as shown in FIG. 3. In some exemplary embodiments, one or more of the lines 636, 638 are discontinuous.

(22) The shingle 600 can be abraded in any manner suitable to remove a portion of the shingle 600 (e.g., at least a portion of the surface coating of granules within the nail zone 630). For example, a moving disk, wheel, belt, or the like with an abrasive surface can be used to form the lines 636, 638 within the nail zone 630. In some exemplary embodiments, the first line 636 is formed and then the second line 638 is formed. In some exemplary embodiments, the lines 636, 638 are formed at the same time. The abraded portion of the shingle 600 (i.e., the lines 636, 638) will have a different appearance than those adjacent portions of the shingle 600 that are unabraded. Consequently, the lines 636, 638 represent a form of nail zone indicia that can be readily and consistently applied to the shingle 600, without requiring application of any additional material (e.g., paint) or component (e.g., reinforcing tape).

(23) In some exemplary embodiments, the width w.sub.2 is greater than ⅛ inch. In some exemplary embodiments, the width w.sub.3 is greater than ⅛ inch. In some exemplary embodiments, the width w.sub.2 is equal to the width w.sub.3. In some exemplary embodiments, the width w.sub.2 is not equal to the width w.sub.3. In some exemplary embodiments, the width w.sub.4 is greater than w.sub.2+w.sub.3. In some exemplary embodiments, the width w.sub.1 is equal to the w.sub.2+w.sub.3+w.sub.4.

(24) Preferably, but not necessarily, the abrasion process occurs in-line during production of the shingle 600.

(25) The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. For example, while various exemplary embodiments are described herein that involve physical abrasion of a shingle, other types of abrasion (e.g., chemical, thermal) may also be suitable. As another example, while various exemplary embodiments are described herein that involve abrasion in a linear manner, other shapes and or patterns of abrasion may also be suitable. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.