Laminated shingle with wider nailing zone

Abstract

A multiple-layer laminated shingle and a method of making the shingle are provided, in which at least one adhesive of high temperature resistance is applied for securing the shingle layers together, to reduce reliance on a roofer having to fasten (via nails, staples or the like) through a narrow headlap zone of a posterior shingle layer in order to secure the posterior shingle layer to a roof, such that a vertically wide portion of the headlap area of the anterior shingle layer is presented to the roofer as a nailing zone.

What is claimed is:  
     
         1 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst;    (e) a first adhesive having heat resistance to a first temperature level and disposed between said shingle layers, securing said layers together; and    (f) a second adhesive having high heat resistance to a second temperature level, higher than said first temperature level, and disposed between said shingle layers, securing said layers together.    
     
     
         2 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) a non-bituminous adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         3 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) an epoxy adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         4 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) a two-part thermal set adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         5 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) a one-part thermal set or moisture cured adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         6 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) a high softening point adhesive having a softening point at least as high as 197° F. and having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         7 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst; and    (e) an adhesive having at approximately at least 150° F. an initial shear modulus greater than 10,000 Newtons/m 2 , and having a shear modulus greater than 1,000 Newtons/m 2  after 1000 seconds of stress exposure induced by constant loading and having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together.    
     
     
         8 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces with at least one cutout extending into the width of the anterior shingle layer an amount terminating in an upper cutout edge;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer and comprising a double layer area, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst;    (e) an adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together;    (f) a visibly marked fastening zone on the front surface of the anterior shingle layer, with said fastening zone being defined by upper and lower demarcation limits;    (g) the upper demarcation limit being opposite the upper area of the rear surface of the anterior shingle layer;    (h) the lower demarcation limit being opposite the lower area of the rear surface of the anterior shingle layer, and above the upper cutout edge of the anterior shingle layer; and    (i) whereby the fastening zone on the anterior shingle layer is, in part, through only the anterior shingle layer.    
     
     
         9 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces with at least one cut out extending into the width of the anterior shingle layer an amount terminating in an upper cut out edge;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer and comprising a double layer area leaving a single thickness upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst;    (e) an adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together;    (f) optional first and second fastening zones on the front surface of the anterior shingle layer and defined by at least three demarcation limits;    (g) the first optional fastening zone being defined by demarcation limits opposite the double layer area and above the upper cut out edge of the anterior shingle layer;    (h) the second optional fastening zone being defined by a demarcation limit opposite the single thickness upper area of the rear surface of the anterior shingle layer and by one of the demarcation limits of clause (g) above, and    (i) whereby a shingle installer has the option of fastening the shingle through either or both of the first and second fastening zones.    
     
     
         10 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst;    (e) an adhesive having heat resistance to a predetermined temperature level and disposed between said shingle layers, securing said layers together;    (f) three demarcation limits on the front surface of the anterior shingle layer, located thereon to comprise means for defining; 
 (i) a first fastening zone for fastening the shingle to a roof by fasteners applied through both anterior and posterior layers; and  
 (ii) a second fastening zone for fastening the shingle to a roof by fasteners applied through only the anterior shingle layer, with said second nailing zone having a majority of its area present only over the front surface of the anterior shingle layer.  
   
     
     
         11 . The shingle of any one of claims  1 - 10 , wherein at least some said adhesive is heat resistant to at least 140° F.  
     
     
         12 . The shingle of any one of claims  1 - 10 , wherein at least some said adhesive is heat resistant to at least 170° F.  
     
     
         13 . The shingle of any one of claims  1 - 10 , wherein at least some said adhesive has a softening point at least as high as 197° F.  
     
     
         14 . The shingle of any one of claims  1 - 10 , wherein at least some said adhesive has a softening point at least as high as 240° F.  
     
     
         15 . The shingle of any one of claims  1 - 10 , wherein at least some said adhesive is selected from the group of ethylene vinyl acetate, polyamide, and polyurethane.  
     
     
         16 . A multi-layer laminated shingle comprising: 
 (a) an anterior shingle layer of a first width between upper and lower edges and having front and rear surfaces;    (b) a posterior shingle layer of a second width, less than the first width, and having front and rear surfaces;    (c) with the anterior shingle layer having upper and lower areas on the rear surface thereof;    (d) with the front surface of the posterior shingle layer being disposed against the lower area of the rear surface of the anterior shingle layer, leaving an upper area of the rear surface of the anterior shingle layer not having the posterior shingle layer disposed thereagainst;    (e) a high heat resistant adhesive having heat resistance to a temperature level and disposed between said shingle layers, securing said layers together; and    (f) said adhesive having no temperature-responsive softening point.    
     
     
         17 . The shingle of any one of claims  8 - 10 , wherein at least some of said demarcation limits comprise marked lines.  
     
     
         18 . The shingle of any one of claims  8 - 10 , wherein at least some of said demarcation limits comprise adhesive lines.  
     
     
         19 . The shingle of any one of claims  8 - 10 , wherein at least some of at least said demarcation limits define at least one band.  
     
     
         20 . The shingle of any one of claims  8 - 10 , wherein the demarcation limits comprise three marked lines, two of which define a double-layer fastening zone, and two of which define a single-layer fastening zone, the single-layer fastening zone having a width that is greater than that of the double layer fastening zone, comprising means presenting fastening zone options of different sizes.