US2008086970A1PendingUtilityA1

Shingles with low density granules and/or backdust

44
Individually held — no corporate assignee on recordPriority: Oct 17, 2006Filed: Oct 17, 2006Published: Apr 17, 2008
Est. expiryOct 17, 2026(~0.2 yrs left)· nominal 20-yr term from priority
Inventors:Yishien H. TengSanjay Mansukhani
E04D 1/26E04D 2001/005B05D 7/24Y10T428/24355B32B 37/24Y10T428/25B32B 2419/06Y10T428/24372Y10T428/31815Y10T428/2438
44
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Claims

Abstract

A roofing shingle has low density granules adhered to at least a headlap region on a front surface of the roof shingle.

Claims

exact text as granted — not AI-modified
1 . A roofing shingle having a front surface comprising a headlap region and a prime region, low density granules adhered to at least the headlap region, wherein the low density granules have a specific gravity between about 0.7 to about 2.3. 
     
     
         2 . The roofing shingle of  claim 1 , wherein the low density granules have an apparent density within a range between about 20 lb/ft 3  and about 70 lb/ft 3 . 
     
     
         3 . The roofing shingle of  claim 1 , wherein the low density granules have a specific gravity in a range between about 1.2 and 1.7. 
     
     
         4 . The roofing shingle of  claim 1 , wherein the low density granules comprise one or more of expanded perlite, expanded shale, expanded clay, expanded slate, pumice, coal slags, metal slags, agglomerated flyash, other agglomerates, and combinations thereof. 
     
     
         5 . The roofing shingle of  claim 1 , wherein the low density granules adhered to the roofing shingle causes a reduction in the wear of a cutting knife and the force used to cut through the roofing shingle when compared with the wear of a knife and cutting of a conventional shingle. 
     
     
         6 . The roofing shingle of  claim 1 , further including low density particles adhered to at least one of: i) the prime region, ii) a back surface of the roofing shingle as backdust, and iii) the prime region and the back surface. 
     
     
         7 . The roofing shingle of  claim 6 , wherein the low density particles have a specific gravity from about 0.7 to about 2.3. 
     
     
         8 . The roofing shingle of  claim 6 , wherein the low density particles have a bulk density within a range between about 20 lb/ft 3  and about 70 lb/ft 3 . 
     
     
         9 . The roofing shingle of  claim 1 , wherein the prime region comprises at least one of: i) prime granules having a specific gravity of at least about 2.5; ii) low density granules having a specific gravity between about 0.7 to about 2.3; and, iii) a mixture of prime granules and low density granules. 
     
     
         10 . The roofing shingle of  claim 1 , wherein the shingle further includes low density granules as filler. 
     
     
         11 . The roofing shingle of  claim 9 , wherein the shingle further includes low density granules as filler. 
     
     
         12 . A method of manufacturing a roofing shingle comprising: coating a substrate with an organic-based coating material, the coated substrate having a front surface with a headlap region and a prime region, and applying low density granules to at least the headlap region, wherein the low density granules have a specific gravity between about 0.7 to about 2.3. 
     
     
         13 . The method of  claim 12 , wherein the densities of headlap and prime granules are different, the method further comprising calculating the weights of prime and headlap regions separately and using the prime region weight as a primary parameter for shingle weight control. 
     
     
         14 . The method of  claim 12 , wherein the low density granules have a bulk density within a range between about 20 lb/ft 3  and about 70 lb/ft 3  and the prime granules have a bulk density of about 80 lb/ft 3  and above. 
     
     
         15 . The method of  claim 12 , wherein the low density granules have a specific gravity in a range between about 1.2 and 1.7. 
     
     
         16 . The method of  claim 12 , wherein the low density granules comprise one or more of expanded perlite, expanded shale, expanded clay, expanded slate, pumice coal slags, metal slags, agglomerated flyash, other agglomerates, and combinations thereof. 
     
     
         17 . The method of  claim 12 , wherein the low density granules applied to the roofing shingle causes a reduction in the wear of a cutting knife used to cut the roofing shingle when compared with the wear of a knife used to cut a conventional shingle. 
     
     
         18 . The method of  claim 12 , further including applying low density particles as at least one of: i) prime granules, ii) backdust on a back surface of the roofing shingle, and iii) prime granules and backdust. 
     
     
         19 . A method of manufacturing a roofing shingle comprising:
 a) applying low density granules as headlap granules on a headlap region of the roofing shingle, wherein the low density granules have a specific gravity between about 0.7 to about 2.3;   b) applying one or more of low density granules or prime granules to a prime region of the roofing shingle, wherein the prime granules have a specific gravity of at least about 2.5; and   c) applying low density particles as backdust on the roofing shingles   
     
     
         20 . The method of  claim 19 , wherein the densities of the headlap granules and the prime granules are different, the method further comprising calculating the weights of the prime and headlap regions separately and using the prime region weight as a primary parameter for shingle weight control. 
     
     
         21 . The method of  claim 19  wherein the low density granules comprise one or more of expanded perlite, expanded shale, expanded clay, expanded slate, pumice, coal slags, metal slags, agglomerated flyash, other agglomerates, and combinations thereof. 
     
     
         22 . A roofing shingle having a front surface comprising a headlap region with headlap material applied thereto, a prime region with prime material applied thereto, a backdust material and a filler material, low density granules being applied as one of the headlap material, prime material, filler material, or backdust materials, wherein the low density granules have a specific gravity between about 0.7 to about 2.3. 
     
     
         23 . The roofing shingle of  claim 23 , wherein the low density granules have an apparent density within a range between about 20 lb/ft 3  and about 70 lb/ft 3 . 
     
     
         24 . The roofing shingle of  claim 23 , wherein the low density granules have a specific gravity in a range between about 1.2 and 1.7. 
     
     
         25 . The roofing shingle of  claim 23 , wherein the low density granules comprise one or more of expanded perlite, expanded shale, expanded clay, expanded slate, pumice, coal slags, metal slags, agglomerated flyash, other agglomerates, and combinations thereof. 
     
     
         26 . The roofing shingle of  claim 23 , wherein low density granules are used as headlap material.

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