Impact resistant shingle

Abstract

An impact resistant shingle is provided, wherein the base mat is impregnated with an asphaltic material, with an asphaltic material on the upper surface of the shingle, and wherein another asphaltic material is disposed on the rear surface of the shingle, which other asphaltic material is softer with greater elongation than the asphaltic material used elsewhere in the shingle, such that crack resistance is afforded because energy from impact on the shingle is dissipated.

1 . An impact resistant shingle having upper and lower surfaces, comprising; 
 (a) a base mat having upper and lower surfaces and impregnated with a first asphaltic material;    (b) the first asphaltic material having an elasticity as determined by a first softness and a first elongation at break;    (c) a second asphaltic material being on the upper surface of the base mat;    (d) a layer of mineral granules being disposed on and adhered to the second asphaltic material on the upper surface of the base mat, and comprising at least a portion of the upper surface of the shingle;    (e) a third asphaltic material being disposed beneath the lower surface of the base mat;    (f) the third asphaltic material being of a second softness that is a softer material than the softness of the first asphaltic material, and of a second elongation at break that is greater than the elongation at break of the first asphaltic material, whereby;    (g) energy from impacts on the upper surface of the shingle is at least partially dissipated at the lower surface of the shingle by the softness and elongation of the third asphaltic material, such that crack formation on the lower surface of the shingle due to impacts on the upper surface of the shingle, is avoided.    
   
   
       2 . The shingle of  claim 1 , wherein the first and second asphaltic materials are of the same formulation.  
   
   
       3 . The shingle of  claim 1 , wherein the first and second asphaltic materials are of different formulations.  
   
   
       4 . The shingle of  claim 1 , wherein the third asphaltic material is disposed against the lower surface of the base mat.  
   
   
       5 . The shingle of  claim 1 , wherein first asphaltic material is disposed against the lower surface of the base mat, and the third asphaltic material is disposed below and adhered to the first asphaltic material.  
   
   
       6 . The shingle of any one of claims  4  and  5 , wherein the third asphaltic material is a liquid-applied coating during the manufacture of the shingle.  
   
   
       7 . The shingle of any one of claims  4  and  5 , wherein the third asphaltic material comprises a sheet of asphaltic material, applied to the shingle in sheet form.  
   
   
       8 . The shingle of any one of claims  1 ,  4  and  5 , wherein the shingle comprises a first thickness layer between upper and lower surfaces thereof, wherein a wind-resistant layer of a second thickness of substantially thinner dimension than that of said first thickness layer, is provided on the lower surface of the first thickness layer, over at least a portion of the lower surface of the first thickness layer, adhered thereto.  
   
   
       9 . The shingle of  claim 8 , wherein the second thickness layer is adhered to the first thickness layer by an asphaltic material.  
   
   
       10 . The shingle of  claim 8 , wherein the second thickness layer is adhered to the first thickness layer by the third asphaltic material.  
   
   
       11 . The shingle of  claim 8 , wherein a granular material is disposed between said first thickness layer and the second thickness layer.  
   
   
       12 . The shingle of  claim 11 , wherein the second thickness layer is adhered to the first thickness layer by an asphaltic material.  
   
   
       13 . The shingle of  claim 11 , wherein the second thickness layer is adhered to the first thickness layer by the third asphaltic material.  
   
   
       14 . The shingle of any one of claims  1 ,  4  and  5 , wherein the third asphaltic material comprises a polymer-modified asphaltic material.  
   
   
       15 . The shingle of  claim 8 , wherein the second thickness layer comprises a material selected from the group consisting of any one of: 
 (a) thin fabric;    (b) plastic film;    (c) paper;    (d) parchment; and    (e) foil;    (f) metal screen;    (g) plastic netting;    (h) glass fibers pressed into the second asphaltic material;    (i) plastic fibers pressed into the second asphaltic material; or    (l) spin blown fibers pressed into the second asphaltic material;    (k) scrim.    
   
   
       16 . The shingle of any one of claims  2  and  3 , wherein the shingle comprises a first thickness layer between upper and lower surfaces thereof; wherein a wind-resistant layer of a second thickness of substantially thinner dimension than that of said first thickness layer, is provided on the lower surface of the first thickness layer, over at least a portion of the lower surface of the first thickness layer, adhered thereto, with the shingle having a butt portion adapted to being substantially covered by another shingle when applied to a roof and a tab portion adapted to being exposed to weather when applied to a roof, wherein the second thickness layer comprises crossing strands of reinforcing material disposed behind the tab portion of the shingle and substantially completely covering the surface behind said tab portion of the shingle.  
   
   
       17 . A shingle according to  claim 1 , wherein the third asphaltic material has an elongation at break of at least two percent.  
   
   
       18 . A shingle according to  claim 17 , wherein the third asphaltic material has an elongation at break of at least two percent measured at about 30° F. after ageing the shingle for at least ten weeks at 158° F.  
   
   
       19 . A shingle according to  claim 17 , wherein the third asphaltic material has a penetration of less than about 150 decimillimeters at 77° F.  
   
   
       20 . A shingle according to  claim 1 , wherein the third asphaltic material is non-adhesive at ambient temperature.  
   
   
       21 . A shingle according to  claim 1 , wherein the third asphaltic material includes a softening composition comprising elastomer and plasticizer.  
   
   
       22 . An impact resistant roofing element having upper and lower surfaces, comprising; 
 (a) a base mat having upper and lower surfaces and impregnated with a first asphaltic material;    (b) the first asphaltic material having an elasticity as determined by a first softness and a first elongation at break;    (c) a second asphaltic material being on the upper surface of the base mat;    (d) a layer of mineral granules being disposed on and adhered to the second asphaltic material on the upper surface of the base mat, and comprising at least a portion of the upper surface of the roofing element;    (e) a third asphaltic material being disposed beneath the lower surface of the base mat;    (f) the third asphaltic material being of a second softness that is a softer material than the softness of the first asphaltic material, and of a second elongation at break that is greater than the elongation at break of the first asphaltic material, whereby;    (g) energy from impacts on the upper surface of the roofing element is at least partially dissipated at the lower surface of the roofing element by the softness and elongation of the third asphaltic material, such that crack formation on the lower surface of the roofing element due to impacts on the upper surface of the roofing element, is avoided.    
   
   
       23 . A shingle according to  claim 1 , wherein the third asphaltic material has self-adhesive properties, the self adhesive properties allowing the product to be adhered to a roofing substrate.  
   
   
       24 . A shingle according to  claim 21 , wherein a lower surface of the third asphaltic material is protected by a release agent surfaced layer, the release agent surfaced layer being removable from the lower surface of the third asphaltic material to expose the self-adhesive third asphaltic material at the lower surface of the shingle.  
   
   
       25 . A method of making an impact resistant roof covering system, comprising the steps of: 
 (a) providing a shingle comprising a first asphaltic material having an elasticity as determined by a first softness and a first elongation at break;    (b) providing a layer of a second asphaltic material of a second softness that is softer than the softness of the first asphaltic material, and of a second elongation at break that is greater than the elongation at break of the first asphaltic material;    (c) applying the layer of the second asphaltic material to a roof substrate; and,    (d) applying the shingle to the roof substrate.    
   
   
       26 . The method according to  claim 23 , wherein the layer of the second asphaltic material is applied to the roof substrate prior to applying the shingle.  
   
   
       27 . The method according to  claim 23 , wherein the layer of the second asphaltic material is applied to a lower surface of the shingle prior to applying the shingle to the roof substrate.