US2006179767A1PendingUtilityA1

Laminated shingle with spacer bands for level stacking

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Individually held — no corporate assignee on recordPriority: Feb 3, 2005Filed: Feb 3, 2005Published: Aug 17, 2006
Est. expiryFeb 3, 2025(expired)· nominal 20-yr term from priority
Inventors:Carla A. MillerBert W. ElliottGerald G. Greaves
B32B 2307/71B32B 2419/06E04D 2001/005B32B 5/24B32B 5/16E04D 1/26B32B 2260/042B32B 3/08B32B 2260/021B32B 5/30B32B 2307/306B32B 5/022B32B 3/30B32B 2307/402
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Claims

Abstract

A roofing shingle includes a shingle overlay sheet, a shingle underlay sheet, and at least one shingle spacer. The underlay sheet and the spacer sheet are secured to the overlay sheet in a manner to prevent humping when the shingles are formed into bundles.

Claims

exact text as granted — not AI-modified
1 . A roofing shingle comprising: 
 a shingle overlay sheet having an upper edge, a lower edge, a top surface, and a rear surface;    a shingle underlay sheet having an upper edge, a lower edge, a top surface, and a rear surface; and    at least one shingle spacer sheet having an upper edge, a lower edge, a top surface, and a rear surface;    wherein the shingle underlay sheet is secured to the rear surface of the shingle overlay sheet and wherein the at least one shingle spacer sheet is provided secured to the rear surface of the shingle overlay sheet.    
     
     
         2 . The roofing shingle according to  claim 1 , wherein the top surface of the spacer sheet and the top surface of the underlay sheet are substantially coplanar.  
     
     
         3 . The roofing shingle according to  claim 1 , wherein the rear surface of the spacer sheet and the rear surface of the underlay sheet are substantially coplanar.  
     
     
         4 . The roofing shingle according to  claim 1 , wherein the spacer sheet is formed integral to the overlay sheet and folded below the rear surface of the overlay sheet.  
     
     
         5 . The roofing shingle according to  claim 1 , wherein the spacer sheet has a first thickness, and the underlay sheet has a second thickness such that the first thickness of the spacer sheet is greater than the second thickness of the underlay sheet.  
     
     
         6 . The roofing shingle according to  claim 5 , wherein the spacer sheet of a first shingle is secured to the first shingle at a position such that, when the first shingle is installed on a roof, the spacer sheet can be used to align the first shingle upon the roof.  
     
     
         7 . The roofing shingle according to  claim 6 , wherein the lower edge of the spacer sheet of a first shingle is configured to abut an upper edge of an overlay sheet of a second shingle similar to the first shingle to align the second shingle to the first shingle.  
     
     
         8 . The roofing shingle according to  claim 1 , wherein the upper edge of the shingle overlay sheet and the upper edge of the shingle spacer sheet are aligned.  
     
     
         9 . The roofing shingle according to  claim 1 , wherein the shingle underlay sheet and the shingle spacer sheet are secured to the rear surface of the shingle overlay sheet such that the lower edge of the shingle spacer sheet and the upper edge of the shingle underlay sheet define a gap therebetween.  
     
     
         10 . The roofing shingle according to  claim 1 , wherein the overlay sheet has a height extending from the lower edge of the overlay sheet to the upper edge of the overlay sheet, the spacer has a height extending from the lower edge of the spacer to the upper edge of the spacer, the underlay sheet has a height extending from the lower edge of the underlay sheet to the upper edge of the underlay sheet, and wherein the height of the overlay sheet is substantially equal to the cumulative heights of the spacer and the underlay sheet.  
     
     
         11 . The roofing shingle according to  claim 1 , wherein the overlay sheet has a height extending from the lower edge of the overlay sheet to the upper edge of the overlay sheet, the underlay sheet comprises at least one tab defining a tab height extending from the lower edge of the underlay sheet to a top end of the tab, and wherein the height of the tab portion is at least half the height of the overlay sheet.  
     
     
         12 . The roofing shingle according to  claim 1 , wherein the shingle underlay sheet is formed from a first material and the spacer sheet is formed from a second material.  
     
     
         13 . The roofing shingle according to  claim 1 , wherein the shingle spacer sheet is selected from a group consisting of tape, cardboard, paper, foam, foamed asphalt, asphalt, cotton shoddy, natural fibers, asphalt coated mat and polymer coated mat materials.  
     
     
         14 . The roofing shingle according to  claim 13 , wherein the shingle spacer sheet comprises a foam material.  
     
     
         15 . The roofing shingle according to  claim 14 , wherein the shingle spacer sheet comprises a foamed asphalt material.  
     
     
         16 . The roofing shingle according to  claim 13 , wherein the shingle spacer sheet comprises a mat coated with an asphalt or polymer material and wherein the spacer sheet provides improved impact resistance.  
     
     
         17 . The roofing shingle according to  claim 1 , wherein the shingle spacer sheet comprises a connector strip, the spacer sheet being secured to the rear surface of the shingle overlay sheet at the upper edge of the spacer sheet and secured to the rear surface of the underlay at the lower edge of the spacer sheet.  
     
     
         18 . A bundle of roofing shingles for at least partially covering a surface, the bundle comprising a plurality of shingles including at least a first shingle and at least a second shingle, wherein each shingle comprises: 
 a shingle overlay sheet having an upper edge and a lower edge, a top surface, and a rear surface, the overlay sheet having a height defined by the distance between the upper edge and the lower edge;    a shingle underlay sheet having an upper edge, a lower edge, a top surface, and a rear surface; and    at least one shingle spacer sheet having an upper edge, a lower edge, a top surface, and a rear surface;    the shingle underlay sheet being secured to the rear surface of the shingle overlay sheet, and the at least one shingle spacer sheet being secured to the rear surface of the shingle overlay sheet,    wherein at least one of the plurality of roofing shingles is stacked upon another of the plurality of roofing shingles in the bundle.    
     
     
         19 . The bundle of roofing shingles according to  claim 18 , wherein the upper edges of the overlay sheet and spacer sheet of the at least first shingle are aligned with the upper edges of the overlay sheet and spacer sheet of the at least second shingle.  
     
     
         20 . The bundle of roofing shingles according to  claim 18 , wherein each shingle has the shingle underlay sheet and the shingle spacer sheet secured to the rear surface of the shingle overlay sheet such that the lower edge of the shingle spacer sheet and the upper edge of the shingle underlay sheet define a gap therebetween.  
     
     
         21 . The bundle of roofing shingles according to  claim 18 , wherein each shingle has the shingle underlay sheet defining a tab portion that is at least half the height of the overlay sheet.  
     
     
         22 . The bundle of roofing shingles according to  claim 18 , wherein each shingle has the shingle underlay sheet having a height defined by a distance between the upper edge and the lower edge thereof, wherein the underlay sheet height is greater than half the height of the overlay sheet.  
     
     
         23 . The bundle of roofing shingles according to  claim 18 , wherein each shingle has the shingle underlay sheet formed from a first material and the spacer sheet formed from a second material.  
     
     
         24 . The bundle of roofing shingles according to  claim 18 , wherein 
 the shingle spacer sheet comprises a foam material.    
     
     
         25 . A method of reducing humping of a bundle of roofing shingles when one or more roofing shingles are stacked with others of the roofing shingles, the roofing shingles being suitable for at least partially covering a roof deck surface, the bundle comprising a plurality of shingles including at least a first shingle and at least a second shingle, wherein the shingles comprise: 
 a shingle overlay sheet having an upper edge, a lower edge, a top surface, and a rear surface;    a shingle underlay sheet having an upper edge, a lower edge, a top surface, and a rear surface; and    at least one shingle spacer sheet having an upper edge, a lower edge, a top surface, and a rear surface;    whereby the method comprises: 
 providing the shingle overlay sheet and the shingle underlay sheet;  
 aligning the shingle underlay sheet with the shingle overlay sheet; and  
 aligning the at least one spacer sheet with the shingle overlay sheet, thereby forming the roofing shingle;  
   wherein the at least one shingle spacer sheet is secured to the rear surface of the shingle overlay sheet.    
     
     
         26 . The method according to  claim 25 , wherein the step of aligning the spacer sheet with the overlay sheet further includes aligning the upper edge of the shingle overlay sheet and the upper edge of the spacer sheet.  
     
     
         27 . The method according to  claim 25 , wherein the shingle underlay sheet and the spacer sheet are secured to the rear surface of the shingle overlay sheet such that lower edge of the spacer sheet and the upper edge of the shingle underlay sheet define a gap therebetween.  
     
     
         28 . The method according to  claim 25 , wherein the method further includes stacking a first one of the roofing shingles upon a second shingle, such that the rear surface of the shingle underlay sheet and the rear surface of the spacer sheet of the first roofing shingle face the top surface of the shingle overlay sheet of the second roofing shingle, and wherein the first and second roofing shingles are further stacked such that the lower edges of the overlay sheet and the underlay sheet of the first roofing shingle are aligned with the lower edges of the overlay sheet and underlay sheet of the second roofing shingle.  
     
     
         29 . The method according to  claim 25 , wherein the method further includes stacking a first one of the roofing shingles upon a second shingle, such that the rear surface of the shingle underlay sheet and the rear surface of the spacer sheet of the first roofing shingle face the top surface of the shingle overlay sheet of the second roofing shingle, and wherein the first and second roofing shingles are further stacked such that the lower edges of the overlay sheet and underlay sheet of the first roofing shingle are aligned with the upper edges of the overlay sheet and the spacer sheet of the second roofing shingle.  
     
     
         30 . The method according to  claim 25 , wherein the method further includes stacking the at least first roofing shingle upon the at least second roofing shingle such that the top surface of the shingle overlay sheet of the first roofing shingle faces the top surface of the shingle overlay sheet of the second roofing shingle, and wherein the first and second roofing shingles are further stacked such that the lower edges of the overlay sheet and underlay sheets of the first roofing shingle are aligned with the lower edges of the overlay sheet and underlay sheet of the second roofing shingle.  
     
     
         31 . The method according to  claim 25 , wherein the method further includes stacking the at least first roofing shingle upon the at least second roofing shingle such that the top surface of the shingle overlay sheet of the first roofing shingle faces the top surface of the shingle overlay sheet of the second roofing shingle, and wherein the first and second roofing shingle are further stacked such that the lower edges of the overlay sheet and underlay sheet of the first roofing shingle are aligned with the upper edges of the overlay sheet and spacer sheet of the second roofing shingle.  
     
     
         32 . The method according to  claim 25 , wherein the method further includes stacking the at least first roofing shingle upon the at least second roofing shingle such that the rear surfaces of the underlay sheet and the spacer sheet of the first roofing shingle face the rear surfaces of the underlay sheet and spacer sheet of the second roofing shingle, and wherein the first and second roofing shingles are further stacked such that the lower edges of the overlay sheet and the underlay sheet of the first roofing shingle are aligned with the lower edges of the overlay sheet and the underlay sheet of the second roofing shingle.  
     
     
         33 . The method according to  claim 25 , wherein the method further includes stacking the at least first roofing shingle upon the at least second roofing shingle such that the rear surfaces of the underlay sheet and the spacer sheet of the first roofing shingle face the rear surfaces of the underlay sheet and spacer sheet of the second roofing shingle, and wherein the first and second roofing shingle are further stacked such that the lower edges of the overlay sheet and the underlay sheet of the first roofing shingle are aligned with the upper edges of the overlay sheet and the spacer sheet of the second roofing shingle.  
     
     
         34 . The method according to  claim 25 , wherein the shingle underlay sheet defines a tab portion that is at least half the height of the overlay sheet.  
     
     
         35 . The method according to  claim 25 , wherein the shingle underlay sheet is formed from a first material and the spacer sheet is formed from a second material.  
     
     
         36 . The method according to  claim 25 , wherein the shingle spacer sheet comprises a foam material.  
     
     
         37 . At least three roofing shingles comprising: 
 a first, second and third shingle overlay sheet, each overlay sheet having an upper edge, a lower edge, a top surface, a rear surface and an overlay height defined by the distance between the upper edge and lower edge thereof;    a first, second and third shingle underlay sheet, each underlay sheet having an upper edge, a lower edge, a top surface, a rear surface and an underlay height defined by the distance between the upper edge and lower edge thereof, each underlay height being greater than half the overlay height;    each shingle underlay sheet being secured to the respective rear surface of a respective one of the shingle overlay sheets adjacent the lower edge of the overlay sheet;    thereafter placing the roofing shingles in a bundle and forming a vertical gap between at least two of said shingles; and    providing at least one spacer sheet for bridging the gap between said at least two shingles.    
     
     
         38 . The roofing shingles of  claim 37 , wherein the at least one shingle spacer sheet is provided secured to the rear surface of one of the shingle overlay sheets.  
     
     
         39 . The roofing shingles of  claim 38 , wherein each of said shingles comprises a shingle spacer sheet secured to the rear surface of one of the shingle overlay sheets.  
     
     
         40 . The roofing shingles of  claim 37 , wherein the at least one shingle spacer sheet is provided secured to the rear surface of one of the shingle underlay sheets.  
     
     
         41 . The roofing shingles according to  claim 39 , wherein the rear surface of the spacer sheets and the rear surface of the underlay sheets are substantially coplanar.  
     
     
         42 . The roofing shingles according to  claim 38 , wherein the spacer sheet has a first thickness, and the underlay sheet has a second thickness such that the first thickness of the spacer sheet is greater than the second thickness of the underlay sheet.  
     
     
         43 . The roofing shingles according to  claim 42 , wherein the spacer sheet of a first shingle is secured to the first shingle at a position such that, when the first shingle is installed on a roof, the spacer sheet can be used to align the first shingle upon the roof.  
     
     
         44 . The roofing shingles according to  claim 37 , wherein the spacer sheet is removed and discarded when the shingles are installed on a roof.  
     
     
         45 . The roofing shingles according to  claim 37 , wherein the shingle spacer sheet is selected from a group consisting of tape, cardboard, paper, foam, asphalt, foamed asphalt, cotton shoddy, natural fibers, and asphalt coated mat and polymer coated mat materials.  
     
     
         46 . The roofing shingles according to  claim 45 , wherein the spacer sheet is removed and discarded when the shingles are installed on a roof.  
     
     
         47 . The roofing shingle according to  claim 37 , wherein the shingle spacer sheet comprises an adhesive material.

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