ROOFING SHINGLES WITH REGISTERED SELF-SEAL STRIP PATTERNS

Abstract

Shingles have self-seal strips with features that include sealant dashes or dots separated by drainage gaps. The self-seal strips are registered with each shingle so that the features are positioned at the same locations on each shingle. A method of making such shingles includes synchronizing the rotation of sealant applicator wheels with the shingle chop cutter so that cuts are made at repeated designated locations along the applied self-seal strips.

Claims

1. A method, comprising: (a) moving a roofing shingle material along a path; (b) progressively applying a sealant material to a surface of the moving roofing shingle material to form a self-seal strip having a pattern of features along its length; wherein the pattern of features of the self-seal strip comprises a plurality drainage gaps defined at a plurality of locations along the self-seal strip; and (c) cutting the roofing shingle material in synchronization with step (b) to form roofing shingles each having at least one self-seal strip with the sealant material located at a plurality of positions along each roofing shingle; wherein the plurality of positions include corners defined between a forward edge and each side edge of each roofing shingle.

2. The method of claim 1, wherein progressively applying the sealant material comprises applying a plurality of dots or dashes of sealant material, wherein at least some of the dots or dashes of sealant material are of different sizes.

3. The method of claim 1, wherein progressively applying the sealant material to the surface of the roofing shingle material comprises depositing a plurality of dots or dashes of sealant material a length of inch to 8 inches along the surface of the moving roofing shingle.

4. The method of claim 1, wherein progressively applying the sealant material comprises applying the sealant material to the surface of the roofing shingle material through at least one slot die to form a plurality of dots or dashes of the sealant material at selected positions along the surface of the roofing shingle material; and controlling a volume of the sealant material supplied to the at least one slot die to vary a length, thickness, a width, density, position, or combinations thereof, of the dots or dashes of sealant material.

5. The method of claim 1, wherein the pattern of features of the self-seal strip includes dots or dashes of sealant material positioned adjacent each corner of each roofing single, and at least one dot or dash of sealant material therebetween and wherein the dots or dashes of sealant material adjacent at each corner of each roofing shingle have a length that is greater than a length of the at least one dot or dash of sealant material disposed therebetween.

6. The method of claim 1, wherein progressively applying the sealant material comprises rotating one or more applicator wheels including a plurality of lands disposed about a peripheral circumference of the one or more applicator wheels; picking up the sealant material from a sump and carrying the sealant material to the surface of the moving roof shingle with the lands; and depositing the sealant material along the surface of the roofing shingle material.

7. A method, comprising: (a) moving a roofing shingle material along a path; (b) applying a sealant material to a surface of the roofing shingle material to form a self-seal strip of the sealant material along the roofing shingle material; and (c) cutting the roofing shingle material in synchronization with step (b) to form roofing shingles each having at least one self-seal strip; wherein the at least one self-seal strip of each of the roofing shingles comprises a pattern of dots or dashes of sealant material located at a plurality of positions along each roofing shingle, and at least one drainage gap defined between at least two adjacent dots or dashes of sealant material; and wherein two or more of the dots or dashes of sealant material have a different thickness, width, length, density, or combinations thereof, based upon a position of the two or more dots or dashes of shingle material along the roofing shingle.

8. The method of claim 7, wherein applying the sealant material to the surface of the roofing shingle material comprises selectively depositing the dashes or dots of the sealant material with a length of inch to 8 inches.

9. The method of claim 7, wherein applying the sealant material includes rotating one or more applicator wheels configured to pick up the sealant material from a supply, and depositing the sealant material along the surface of the roofing shingle material.

10. The method of claim 9, wherein each of the one or more applicator wheels includes a hub, a plurality of lands configured to pick up and carry the sealant material to the surface of the roofing shingle material, and gaps separating each land; wherein at least some of the lands are of different sizes so as to deposit different size dots or dashes of sealant material along the surface of the roofing shingle material.

11. The method of claim 7, wherein each of the roofing shingles comprises an upper surface having a headlap portion configured to be overlapped by a next roofing shingle in a next higher course of roofing shingles and an exposure portion; and a lower surface opposite the upper surface; and wherein applying the sealant material comprises applying the dots or dashes of the sealant material to the lower surface opposite the exposure portion.

12. The method of claim 11, wherein the exposure portion further comprises a series of teeth, and wherein applying the sealant material comprises applying the dots or dashes of sealant material to the lower surface at spaced positions relative to positions of the teeth of the exposure portion.

13. The method of claim 7, wherein the pattern of dots or dashes of sealant material includes dots or dashes of sealant material positioned adjacent each side edge of each roofing shingle, and at least one dot or dash of sealant material therebetween; and wherein the dots or dashes of sealant material adjacent at each side edge of each roofing shingle have a length that is greater than a length of the at least one dot or dash of sealant material disposed therebetween.

14. A roof, comprising: a roof deck; a plurality of roofing shingles positioned on the roof deck; wherein each of the roofing shingles comprises: an upper surface having a headlap portion configured to be overlapped by a next roofing shingle in a next higher course of roofing shingles and an exposure portion; a lower surface opposite the upper surface; and at least one self-seal strip applied to the lower surface, the self-seal strip extending along a length of the roofing shingle; wherein the at least one self-seal strip comprises a pattern of dots or dashes of a sealant material applied along the lower surface at a plurality of positions adjacent a forward edge of the roofing shingle, with at least one drainage gap defined between at least two adjacent dots or dashes of sealant material; wherein the pattern of dots or dashes of sealant material comprises two or more dots or dashes of sealant material having different sizes; wherein the roofing shingles are arranged in overlapping courses on the roof deck with the headlap portion of each roofing shingle in a lower course of roofing shingles engaging a self-seal strip of an overlapping roofing shingle in a higher course of roofing shingles along a portion of a forward edge thereof.

15. The roof of claim 14, wherein the dashes or dots have a length from inch to 8 inches.

16. The roof of claim 15, wherein the drainage gaps have a length from inch to 4 inches.

17. The roof of claim 14, wherein the pattern of dots or dashes of sealant material includes a dot or dash of sealant material positioned at a corner defined between the forward edge and each side edge of the roofing shingle, and at least one dot or dash of sealant material disposed therebetween and separated from the dots or dashes of sealant material at each corner by a drainage gap; and wherein the dots or dashes of sealant material at each corner have a length that is different from a length of the at least one dot or dash of sealant material disposed therebetween.

18. The roof of claim 14, wherein a length of at least some of the dots or dashes of sealant material increases as the dots or dashes are positioned toward each side edge of the roofing shingles, and wherein a length of the drainage gaps decreases as the drainage gaps are positioned toward each side edge of the roofing shingles.

19. The roof of claim 14, wherein the exposure portion further comprises a series of teeth, and wherein the dots or dashes of sealant material of the self-seal strip are applied to the lower surface of each roofing shingle in positions relative to positions of the teeth.

20. The roof of claim 19, wherein the dots or dashes of sealant material of the self-seal strip comprise at least two rows of dots or dashes of sealant material extending along the lower surface of the roofing shingle; wherein at least one row of the dots or dashes of sealant material are positioned opposite the teeth of the exposure portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.

[0014] FIG. 1 shows a shingle with a self-seal strip having a uniform dash and gap pattern aligned with the shingle so that a dash always appears at each end of the shingle.

[0015] FIG. 2 shows a shingle with a self-seal strip having a semi-continuous dash and gap pattern with dashes at the ends of the shingle and in the mid-portion of the shingle and with water drainage gaps at strategic locations.

[0016] FIG. 3 shows a shingle with a self-seal strip registered with the shingle and made of sealant dashes and gaps of varying lengths in an optimized pattern.

[0017] FIG. 4 illustrates application of the self-seal strip of FIG. 1 to a length of shingle stock during manufacture in such a way that the self-seal strip of each shingle is registered when shingles are cut from the shingle stock.

[0018] FIG. 5 illustrates application of the self-seal strip of FIG. 2 to a length of shingle stock during manufacture in such a way that the self-seal strip of each shingle is registered when shingles are cut from the shingle stock.

[0019] FIG. 6 illustrates application of the self-seal strip of FIG. 3 to a length of shingle stock during manufacture in such a way that the self-seal strip of each shingle is registered when shingles are cut from the shingle stock.

[0020] FIG. 7 shows self-seal strips applied to dragon teeth shingles and registered with the shingles to form a desired pattern on each dragon tooth of each shingle.

[0021] FIG. 8 shows application of the self-seal strips of FIG. 7 to a strip of shingle stock before the stock is cut into dragon teeth shingles.

[0022] FIG. 9 illustrates a sealant application wheel usable to create the self-seal strip pattern of FIG. 1.

[0023] FIG. 10 illustrates a sealant application wheel usable to create the self-seal strip pattern of FIG. 2.

[0024] FIG. 11 illustrates a sealant application wheel usable to create the self-seal strip pattern of FIG. 3.

DETAILED DESCRIPTION

[0025] The following description is provided as an enabling teaching of embodiments of this disclosure. Those skilled in the relevant art will recognize that many changes can be made to the embodiments described, while still obtaining the beneficial results. It will also be apparent that some of the desired benefits of the embodiments described can be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments of the disclosure and not in limitation thereof, since the scope of the present disclosure is defined by the claims.

[0026] FIG. 1 shows the bottom surface of a shingle 11 with a self-seal strip according to an embodiment of the present disclosure. The shingle 11 may be a multi-layer architectural shingle such as a Timberline brand shingle available from GAF. Such a shingle has another layer such as a dragon teeth layer (not visible) on its top surface. The shingle 11 is rectangular in shape and has a self-seal strip 12 applied to its bottom surface adjacent the forward edge 9 of the shingle.

[0027] The self-seal strip 12 is made up of features that, in this example, comprise a series of sealant dashes 13 separated by gaps 14. In some embodiments, features may include, but are not limited to, sealant dashes, sealant dots, gaps with no sealant, dashes with varying length, dashes with varying thickness, dashes with varying density, etc. In addition, while a single self-seal strip or line of sealant material is shown, in some embodiments, multiple lines of sealant materials also can be applied; for example, a second self-seal strip or line of sealant material could be applied to the lower surface of the shingle 9, spaced rearward from the forward edge 9 and self-seal strip 12.

[0028] In addition, in some embodiments such as shown in FIG. 1, the lengths of the sealant dashes 13 can be substantially constant and the lengths of the gaps also can be substantially constant. For example, as illustrated in FIG. 1, a pair of sealant dashes or other lengths of sealant material can be applied to the lower surface of the roofing shingle, extending from intermediate positions along the length of the roofing shingle to the side edges and/or the corners defined between the forward edge and each side edge, with a drainage gap separating the pair of sealant features. However, unlike the prior art, the self-seal strip (or strips if multiple self-seal strips are provided) is registered with the shingle such that a full sealant dash is located at each end of the shingle. While this is a simple pattern, it ensures that the forward edge of the shingle is always sealed adequately at its ends to an underlying shingle. This, in turn, provides reliable wind lift resistance at the ends of each shingle where wind lift is most prominent.

[0029] FIG. 2 illustrates the bottom surface of a shingle 16 having a self-seal strip 17 applied adjacent its forward edge 9. In this example, the self-seal strip 17 is semi-continuous in that it is made up of sealant dashes at each end (e.g., each side edge) of the shingle, a long sealant dash 18 in the mid-portion of the shingle, and a pair of gaps 19 separating the sealant dashes at the ends from the sealant dash in the mid-portion. Generally, but without limitation, a length of the sealant dashes at the ends of the shingle may be from inch to 8 inches long and a length of the gaps 19 may be from inch to 4 inches long. In other embodiments, the length of the sealant dashes can vary from 1 inch to 8 inches, 1 to 7 inches, 2 to 7 inches, 2 to 6/12 inches, 3 to 6 inches, 3 to 5 inches, or 4 to 5 inches; while the length of the gaps can vary from to 3/12 inches, to 3 inches, to 2 inches, to 2 inches, to 1 inches, or to 1 inches. Other lengths and/or configurations of the sealant dashes and gaps therebetween also can be used.

[0030] As shown in FIG. 2, dash 18 generally spans the remainder of the width of the shingle. The self-seal strip 17 is registered with the shingle 16 so that the sealant dashes and the water drainage gaps are positioned at various locations along the length of the shingle 16. A shingle of this example can provide enhanced adhesion between shingles but positions drainage gaps at locations where they are most effective.

[0031] FIG. 3 illustrates the bottom surface of a rectangular shingle 21 having a self-seal strip 22 applied to the shingle adjacent its forward edge 9. Here, the self-seal strip 22 is made up of sealant dashes 23 separated by gaps 24. The lengths of the sealant dashes 23 vary along the length of the self-seal strip and the lengths of the gaps 24 also vary. For instance, the sealant dashes 23 are shortest in a mid-portion of the shingle and become gradually longer toward end portions of the shingle (e.g., a length of the dots or dashes of the plurality of dots or dashes increases as the dots or dashes are positioned toward side edges of the roofing shingle). Likewise, the gaps are largest in the mid-portion of the shingle and become smaller toward the end portions of the shingle (e.g., a length of the drainage gaps decreases as the drainage gaps are positioned toward side edges of the roofing shingle). A longer sealant dash is located at each end of the shingle.

[0032] The self-seal strip of this embodiment may be referred to as an optimized self-seal strip, meaning that the amount of adhesion and water drainage capabilities vary along the shingle according to the adhesion and draining needs at various locations. For instance, more sealant is located at the ends of the shingle where wind lift resistance is most needed while less sealant is used in the mid-portion of the shingle where wind lift forces are lowest. The sealant is applied only where it is required and only in the amounts required, thereby minimizing sealant usage while maintaining maximum performance.

[0033] FIG. 4 shows a self-seal strip 27 of the type shown in FIG. 1 applied to a length of shingle stock 26 during manufacture and before shingles are cut from the stock. Vertical lines indicate locations where the strip will later be cut by a chop cutter and three complete shingles are illustrated. As discussed below, the self-seal strip may be applied with an application wheel that, in this embodiment, has a peripheral circumference three times the length of a single shingle. FIG. 4 (and FIGS. 5 and 6) show the results of one rotation of the application wheel.

[0034] It can be seen that the self-seal strip 27 of FIG. 4 is made up of sealant dashes separated by gaps and that the self-seal strip is registered with the cutting locations to provide the same self-seal strip pattern on each shingle once cut. For example, a longer sealant dash is centered on each cutting location. When the strip of shingle stock is cut at these locations, a sealant dash ends up at each end of each shingle to provide wind lift resistance at the ends (see resulting individual shingles in FIG. 1).

[0035] Similarly, FIG. 5 shows a self-seal strip 29 of the type shown in FIG. 2 applied to a length of shingle stock 28 during manufacture before shingles are cut from the stock. When cut at the indicated cutting locations, each shingle will bear the same semi-continuous self-seal strip pattern with sealant dashes at the ends of each shingle, a continuous sealant dash in the mid-portion of the shingle, and drainage gaps between the sealant dashes.

[0036] FIG. 6 shows a self-seal strip 32 of the type shown in FIG. 3 applied to a length of shingle stock 31 during manufacture before shingles are cut from the stock. The self-seal strip is registered with the shingle stock so that when it is cut into shingles at the indicated locations, the optimized self-seal strip pattern of FIG. 3 appears on each shingle.

[0037] FIG. 7 illustrates principles of the present disclosure applied to the bottom surfaces of shingles that are laminated prior to being cut into dragon teeth patterns. An example of such shingles is Grand Canyon brand shingles available from GAF. The principles of the present disclosure also can be applied to non-laminated shingles cut into dragon teeth patterns, or other patterns. Self-seal strips 36 and 37 are applied to the bottom surfaces of dragon teeth 34 and 39 and self-seal strips 40 are applied just above the cutouts of each shingle. When the shingles are installed in overlapping courses on a roof, the self-seal strips of shingles in one course adhere to shingles in the next lower course to secure the courses together and prevent wind lift. Further, a drainage gap is provided for most or all of the dragon teeth.

[0038] To accomplish this, a pair of self-seal strips is applied along the length of each dragon tooth as shown at 36 and 37 in FIG. 7. These self-seal strips are registered with the shingle to obtain a consistent dash-and-gap pattern on the bottom surface of most or all of the dragon teeth 34 and 39. The pattern in FIG. 7, for instance, is two spaced rows of self-seal strips on selected dragon teeth. For most dragon teeth, the strip is characterized by sealant dashes at the ends of the dragon tooth separated by a drainage gap between the dashes. In the example of FIG. 7, a third self-seal strip 40 is applied to the bottom surface of each shingle. The self-seal strip 40 is registered with the shingle so that a longer dash of sealant is applied just above each cutout. The self-seal strip 40 adheres shingles to underlying shingles to form a moisture barrier above the cutouts.

[0039] FIG. 8 shows the bottom surface of a strip of shingle stock 41 during manufacture of shingles such as those of FIG. 7 and before the strip is cut into individual shingles. The outlines of the eventual cuts are shown. As detailed below, a sealant applicator wheel may be synchronized with the cutter that will cut the strip at the outlines so that the desired self-seal strip patterns 40, 42, and 43 will appear on each dragon tooth and above each cutout when the strip 41 is cut.

[0040] FIG. 9 illustrates an example of a sealant applicator wheel for creating the self-seal strip pattern shown in FIG. 1. As is known in the art, sealant applicator wheels typically have peripheral lands separated by gaps. The wheels rotate below a web of moving shingle stock. As the applicator wheels rotate, their lands pick up sealant from a sump and carry the sealant up to the surface of the shingle stock, where the lands kiss or engage the shingle stock and deposit the picked-up sealant. In FIG. 9, sealant applicator wheel 44 has a thin cylindrical hub 46. The periphery of the sealant applicator wheel carries an array of raised lands 47 separated by gaps.

[0041] Three of the lands 48 in this example are spaced at 120 degree increments around the wheel and have a surface length longer than the surface lengths of the other lands. The peripheral circumference of the applicator wheel of FIG. 9 is three times the length of a shingle so that a single rotation of the applicator wheel applies a self-seal strip to a length of shingle stock that will become three individual shingles. Rotation of the sealant applicator wheel is synchronized with operation of the downstream chop cutter. The longer lands 48 are positioned to deposit longer sealant dashes that span cutting locations on a length of shingle stock to create sealant dashes at the ends of shingles cut from the stock.

[0042] According to aspects of the present disclosure, the sealant application wheel 44 has a peripheral circumference that is a multiple of the final shingle length. In FIG. 9, for instance, the wheel 44 has a circumference that the three times the length of a shingle. The lands 47 are positioned on the wheel 44 to correspond to locations on finished shingles where sealant dashes are desired or needed. The spaces between lands are positioned to correspond to locations where drainage gaps are desired or needed. As mentioned, rotation of the sealant application wheel is synchronized with the operation of a downstream chop cutter that will cut the shingle stock into individual shingles.

[0043] Synchronization of sealant applicator wheels with the chop cutter can be established in various ways. In one embodiment, a fixed length is established between the sealant applicator wheel or wheels and the downstream chop cutter. In this way, the shingle stock is cut at specific and repeating locations relative to the features of the applied self-seal strips. In an alternative embodiment, servo or stepper motors controlled by a controller or artificial intelligence software may control operation of the chop cutter and/or the sealant applicator wheels to insure that shingles are cut at desired locations relative to the features of applied self-seal strips. For example, rotation of the sealant applicator wheels and or rotation of the chop cutter may be varied based upon the varying path length from the measurement of the free loop length. In each embodiment, applied self-seal strips are registered with all the shingles cut from the ribbon of shingle stock.

[0044] The sealant applicator wheel of FIG. 9, referred to as the wind lift resistant corners wheel, applies a longer dash of sealant from its longer lands 48 that extends on either side of each cut location between shingles. The result are shingles such as those shown in FIG. 1 with sealant dashes that always are positioned at the ends of the shingle.

[0045] FIG. 10 shows a sealant applicator wheel 49 that may be used to apply semi-continuous self-seal strips, such as those shown in FIG. 2. The wheel 49 has a hub 51, long peripheral lands 52, and three short lands 53 with the lands being separated by gaps 54. This sealant applicator wheel 49, and the other embodiments discussed herein, has a peripheral circumference that is three times the length of a single shingle. This is not limiting, however, as other multiples of shingle length are possible. As the wheel 49 rotates, it picks up sealant from a sump and applies the sealant to shingle stock in such a way that the shingles of FIG. 2 are created. The resulting self-seal strip patterns provides complete bonding for substantially the full length of the shingle and also provides gaps located to allow water to drain at key locations. This, in turn, can prevent, reduce, or inhibit leaks behind the shingles.

[0046] FIG. 11 illustrates another embodiment of a sealant applicator wheel 56 configured to apply optimized self-seal strip patterns such as those shown in FIG. 3. Here, the hub 57 has peripheral lands 58 that vary in length around the periphery of the wheel. Longer lands are located at positions that will correspond to cut locations along the shingle stock. The lands 58 are separated by gaps 59. The sealant applicator wheel 56 of FIG. 11 applies a reduced amount of sealant where it is not needed to maintain excellent performance. This reduces sealant needed per shingle and therefore reduces product cost with no performance degradation.

[0047] In other embodiments, the sealant pattern of dots, dashes, etc. . . . may be applied by various different applicators other than an applicator wheel. For example, the sealant may be ejected onto the lands (or directly onto moving shingle stock) from a slot die such as that shown in U.S. Pat. No. 9,795,981 owned by the applicant of the present application and incorporated herein by reference. In such an embodiment, the volume of sealant delivered to the slot die may be varied and synchronized with rotation of the sealant applicator wheel or movement of the shingle stock. Shingles resulting from such an embodiment may have self-seal strips that not only are registered with the shingles as discussed above, but that can vary in other features such as thickness, density, and width to name a few. Each dash and each gap can thus be custom tailored for its specific location on a shingle. For instance, and without limitation, thinner or narrower or less dense adhesive dashes can be applied where less adhesion is needed and thicker or wider adhesive dashes can be applied where more adhesion is needed. With this embodiment, the use and placement of adhesive can be finely tuned to result in the absolute least amount of adhesive use while maintaining superior performance.

[0048] The foregoing description generally illustrates and describes various embodiments of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present disclosure. Accordingly, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.