Low-cost highly aesthetic and durable shingle

Abstract

A ridge cover is formed of inorganic (glass) felt-like sheet material fill-coated with an asphaltic material modified to improve its flexibility. The sheet material is repeatedly back bent upon itself to provide a thickened portion for the ridge cover. The flexible asphaltic material surprisingly allows such back bending of the sheet material substantially without fracture of the glass fibers of the inorganic felt at the bends.

We claim: 
     
       1. A ridge cover for roofing, said ridge cover comprising: an elongate sheet of flexible and durable composition roofing material which is substantially uniform through its thickness, said sheet including a sheet-like base of felted inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and at least three percent by weight of a flexibility improving additive selected from the group including styrene-butadiene-styrene, and atactic polypropylene;   said ridge cover further including on a top side thereof a coating of said modified asphaltic material adhering thereto an upper layer of granular mineral material;   said elongate sheet of composite roofing material being transversely back folded on itself at least twice at spaced apart fold lines intermediate the length of said sheet to define a transverse comparatively thickened portion for said ridge cover, and said modified asphaltic matrix material distributing folding stresses within said back folds to prevent fracture of said sheet-like base of felted inorganic fibers, said transverse thickened portion connecting comparatively thinner and elongate respective upper and lower portions of said cover member disposed on each side thereof;   said elongate sheet further including a T-shaped through slit at said thickened portion and extending into an adjacent part said upper portion of said cover member, said sheet being folded lengthwise on itself with said upper layer of granular material outwardly to a shipping position in which said upper and lower portions define respective longitudinal fold lines, and said T-shaped slit opening to allow said transverse thickened portion to also fold and to be sandwiched within said adjacent part of said upper portion, said modified asphaltic matrix material also distributing folding stresses at said longitudinal fold lines to prevent fracture of said sheet-like base of felted inorganic fibers.   
     
     
       2. The ridge cover of claim 1 wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of from about three percent to about .[.ten.]. .Iadd.twelve .Iaddend.percent. 
     
     
       3. The ridge cover of claim 2 wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of substantially seven percent. 
     
     
       4. The ridge cover of claim 1 wherein said elongate sheet is of trapezoidal shape. 
     
     
       5. The ridge cover of claim 4 wherein said trapezoidal shape has a length of from about 213/4 inches to about 241/4 inches. 
     
     
       6. The ridge cover of claim 5 wherein said trapezoidal shape has a wider end edge of from about 73/4 inch to about 93/4 inch, and a narrower end edge of from about 5 inches to about 8 inches. 
     
     
       7. The ridge cover of claim 6 wherein said comparatively thinner and elongate lower portion has a length from said wider end edge to said thickened portion of from about 6 inches to about 9 inches. 
     
     
       8. The ridge cover of claim 7 wherein said T-shaped slit has a length of from about 55/8 inches to about 75/8 inches. 
     
     
       9. As an article of manufacture, a ridge cover for roofing which at an intermediate stage of manufacture comprises an elongate trapezoidally-shaped sheet of composition roofing material, said roofing material sheet including a base sheet with a sheet-like felt of inorganic fibers in a matrix of modified asphaltic material and being materially uniform throughout its thickness, said modified asphaltic material including asphalt and a flexibility improving additive selected from the group including styrene-butadiene-styrene and atactic polypropylene, said flexibility improving additive being added to said asphalt at a weight percentage of from about three percent to about ten percent, and said article including a T-shaped longitudinal slit having a cross bar portion disposed toward a narrower end of said trapezoidal shape. 
     
     
       10. The article of manufacture of claim 9 wherein said trapezoidally-shaped sheet is free of transverse score lines aligned transversely to an upright portion of said T-shaped slit as preparations for back folding of said article on itself. 
     
     
       11. The article of manufacture of claim 9 wherein said trapezoidal-shaped sheet has a length of from about .[.211/4.]. .Iadd.213/4.Iaddend. inches to about 241/4 inches. 
     
     
       12. The article of manufacture of claim 9 wherein said trapezoidally-shaped sheet has a wider end edge of from about 73/4 inches to about 93/4 inches wide. 
     
     
       13. The article of manufacture of claim 12 wherein said trapezoidally-shaped sheet has a narrower end edge of from about 5 inches to about 8 inches wide. 
     
     
       14. The article of manufacture of claim 13 wherein said T-shaped slit has a length of from about 6 inches to about 9 inches. 
     
     
       15. A method of providing an inorganic composition ridge cover for roofing, said method comprising the steps of: providing a felt-like sheet of inorganic fibrous material;   providing a modified asphaltic material including asphalt and a flexibility improving additive;   selecting said flexibility improving additive from the group including styrene-butadiene-styrene and atactic polypropylene;   adding said flexibility improving additive to said asphalt at a weight percentage of from about three percent to about ten percent;   employing a high-shear .[.mixer.]. .Iadd.mixer/blender .Iaddend.to combine said asphalt and said flexibility improving additive;   fill coating said felt-like sheet of inorganic fibrous material with said asphaltic material to provide a materially uniform base sheet for said ridge cover;   back bending said base sheet on itself to provide a thickened region in said ridge cover; and   while back bending said base sheet on itself employing said asphaltic material to distribute bending forces in said materially uniform base sheet and substantially preventing fracture of the inorganic fibers of said felt-like sheet at said back bend.   
     
     
       16. The method of claim 15 wherein said selecting step includes the selection of said styrene-butadiene-styrene. 
     
     
       17. The method of claim 15 wherein said adding step includes the addition of said flexibility improving additive at substantially seven percent by weight to said asphalt. 
     
     
       18. The method of claim 15 wherein said combining of said flexibility improving additive and said asphalt with said high sheer .[.mixer.]. .Iadd.mixer/blender .Iaddend.further includes the step of heating the materials during combination to about 350° F. 
     
     
       19. The method of claim 15 further including the steps of providing an outer layer of said modified asphaltic material on said base sheet, and employing said outer layer to adhere a granular mineral material on said ridge cover. 
     
     
       20. The method of claim 19 further including the steps of cutting a portion of said base sheet with said outer layer of asphaltic material and outer layer of granular material thereon to an elongate trapezoidal shape, forming a longitudinally extending T-shaped slit in said trapezoidally shaped portion, and repeatedly back bending said sheet portion on itself intermediate its length and at bend lines transverse to said T-shaped slit without formation of preparatory score lines at said bend lines to provide said thickened portion in said ridge cover. 
     
     
       21. A ridge cover for roofing, said ridge cover comprising: an elongate sheet of flexible and durable composition roofing material which is substantially uniform through its thickness, said sheet including a permeable sheet-like base of inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and at least three percent by weight of a flexibility improving additive;   said ridge cover further including on a top side thereof a coating of said modified asphaltic material adhering thereto an upper layer of granular mineral material;   said elongate sheet of composite roofing material being transversely back folded on itself at least twice at spaced apart fold lines intermediate the length of said sheet to define a transverse comparatively thickened portion for said ridge cover, and said modified asphaltic matrix material distributing folding stresses within said back folds to prevent fracture of said sheet-like base of inorganic fibers, said transverse thickened portion connecting comparatively thinner and elongate respective upper and lower portions of said cover member disposed on each side thereof;   said elongate sheet further including a T-shaped through slit at said thickened portion and extending into an adjacent part said upper portion of said cover member, said sheet being folded lengthwise on itself with said upper layer of granular material outwardly to a shipping position in which said upper and lower portions define respective longitudinal fold lines, and said T-shaped slit opening to allow said transverse thickened portion to also fold and to be sandwiched within said adjacent part of said upper portion, said modified asphaltic matrix material also distributing folding stresses at said longitudinal fold lines to prevent fracture of said sheet-like base of inorganic fibers.   
     
     
       22. The ridge cover of claim 21 wherein said flexibility improving additive is an elastomeric polymer. 
     
     
       23. The ridge cover of claim 22 wherein said flexibility improving additive is selected from the group including styrene-butadiene-styrene, and atactic polypropylene. 
     
     
       24. The ridge cover of claim 21 wherein said sheet-like base of inorganic fibers is felted material. 
     
     
       25. The ridge cover of claim 21 wherein said sheet-like base of inorganic fibers is woven material. .Iadd.26. A ridge cover for roofing, said ridge cover comprising: a sheet of flexible composition roofing material which is substantially uniform through its thickness, said sheet including a permeable sheet-like base of felted inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and at least three percent by weight of a flexibility improving additive selected from the group consisting of: styrene-butadiene-styrene, and atactic polypropylene;   said ridge cover further including on a top side thereof a coating of said modified asphaltic material, said coating of modified asphaltic material adhering an upper layer of granular mineral material;   said sheet of composite roofing material being back folded on itself, and said modified asphaltic matrix material distributing folding stresses within said back folds to prevent fracture of said sheet-like base of felted inorganic fibers..Iaddend..Iadd.27. The ridge cover of claim 26 wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of from about three percent to about twelve percent..Iaddend..Iadd.28. The ridge cover of claim 26 wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of substantially seven   
     
     
        percent..Iaddend..Iadd.29.  A method of providing an inorganic composition ridge cover for roofing, said method comprising the steps of: providing a felt-like sheet of inorganic fibrous material;   providing a modified asphaltic material including asphalt and a flexibility improving additive;   selecting said flexibility improving additive from the group consisting of: styrene-butadiene-styrene and atactic polypropylene;   adding said flexibility improving additive to said asphalt at a weight percentage of from about three percent to about ten percent;   mixing together said asphalt and said flexibility improving additive;   fill coating said felt-like sheet of inorganic fibrous material with said modified asphaltic material to provide a materially uniform base sheet for said ridge cover;   back bending said base sheet on itself; and   while back bending said base sheet on itself employing said modified asphaltic material to distribute bending forces in said materially uniform base sheet and to substantially prevent fracturing of the inorganic fibers of said felt-like sheet at said back bend..Iaddend..Iadd.30. The method of claim 29 wherein said selecting step includes the step of selecting styrene-butadiene-styrene as said flexibility improving additive..Iaddend..Iadd.31. The method of claim 29 further including the steps of providing an outer layer of said modified asphaltic material on said base sheet, and employing said outer layer of modified asphaltic material to adhere a layer of granular mineral material on said ridge   
     
     
        cover..Iaddend..Iadd.32.  A ridge cover for roofing, said ridge cover comprising: a sheet of flexible and durable composition roofing material which is substantially uniform through its thickness, said sheet including a permeable sheet-like base of inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and at least three percent by weight of a flexibility improving additive;   said ridge cover further including on a top side thereof a coating of said modified asphaltic material adhering thereto an upper layer of granular mineral material;   said sheet of composite roofing material being back folded on itself to form a fold line, and said modified asphaltic matrix material distributing folding stresses within said back fold to prevent fracture of said sheet-like base of inorganic fibers..Iaddend..Iadd.33. The ridge cover of claim 32 wherein said flexibility improving additive is an elastomeric polymer..Iaddend..Iadd.34. The ridge cover of claim 32 wherein said flexibility improving additive is selected from the group consisting of: styrene-butadiene-styrene, and atactic polypropylene..Iaddend..Iadd.35. The ridge cover of claim 32 wherein said sheet-like base of inorganic fibers is felted material..Iaddend..Iadd.36. The ridge cover of claim 32 wherein said sheet-like base of inorganic fibers is woven material..Iaddend..Iadd.37. The ridge cover of claim 32 wherein said inorganic fibers of said sheet-like base are glass   
     
     
        fibers..Iaddend..Iadd.  .  A ridge cover for roofing, said ridge cover being formed of sheet inorganic asphaltic composition roofing material which is back folded on itself to provide in increased thickness and an appearance of thickness for the ridge cover as installed on a roof, said ridge cover comprising: a sheet of flexible inorganic asphaltic composition roofing material which is substantially uniform through its thickness, said sheet including a sheet-like base of felted inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and at least three percent by weight of a flexibility improving additive selected from the group consisting of: styrene-butadiene-styrene, and atactic polypropylene;   said ridge cover further including on a top side thereof a coating of said modified asphaltic matrix material, said coating of modified asphaltic matrix material adhering an upper layer of granular mineral material;   said sheet of inorganic asphaltic composition roofing material being back folded on itself to form a thickening in said ridge cover, and said modified asphaltic matrix material distributing folding stresses within said back fold to prevent fracture of said sheet-like base of felted inorganic fibers..Iaddend..Iadd.39. The ridge cover of claim 26 wherein said flexibility improving additive is included in said modified asphaltic matrix material at a weight percentage of from about three percent to about twelve percent..Iaddend..Iadd.40. The ridge cover of claim 26 wherein said flexibility improving additive is included in said modified asphaltic matrix material at a weight percentage of substantially seven   
     
     
        percent..Iaddend..Iadd.41.  A ridge cover for roofing, said ridge cover comprising: a sheet of flexible composition roofing material which is substantially uniform through its thickness, said sheet including a sheet-like base of felted inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and a flexibility improving additive;   said sheet of composite roofing material being back folded on itself, and said modified asphaltic matrix material distributing folding stresses within said back fold;   wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of at least three about   
     
     
        percent..Iaddend..Iadd.42.  The ridge cover of claim 41 wherein said sheet further includes on a top side there of a coating of said modified asphaltic material, said coating of modified asphaltic material adhering an upper layer of granular mineral material..Iaddend..Iadd.43. The ridge cover of claim 41 wherein said flexibility improving additive is included in said modified asphaltic material at a weight percentage of from about three percent to about twelve percent..Iaddend..Iadd.44. The ridge cover of claim 41 wherein said flexibility improving additive is selected from the group consisting of: styrene-butadiene-styrene, and atactic polypropylene..Iaddend..Iadd.45. The ridge cover of claim 41 wherein said sheet is back folded on itself at least twice..Iaddend..Iadd.46. A method of providing an inorganic composition ridge cover for roofing, said method comprising the steps of: providing a felt-like base sheet of inorganic fibrous material through impregnated with a modified asphaltic material including asphalt and a flexibility improving additive;   providing said flexibility improving additive in said modified asphaltic material at a weight percentage of at least three percent;   back bending said base sheet on itself;   wherein, while back bending said base sheet on itself said modified asphaltic material distributes bending forces in said base sheet..Iaddend..Iadd.47. The method of claim 46 wherein said selecting step includes the step of selecting styrene-butadiene-styrene as said flexibility improving additive..Iaddend..Iadd.48. The method of claim 46 wherein said selecting step includes the step of selecting atactic polypropylene as said flexibility improving additive..Iaddend..Iadd.49. A ridge cover for roofing, said ridge cover comprising:   a sheet of flexible and durable composition roofing material which is substantially uniform through its thickness, said sheet including a permeable sheet-like base of inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and a flexibility improving additive which is present in said modified asphaltic matrix material at a weight percentage of at least about three percent;   said sheet of composition roofing material being back folded on itself to form a fold line, and said modified asphaltic matrix material distributing folding stresses within said back fold so as to substantially prevent fracturing of the fibers of said sheet-like base of inorganic   
     
     
        fibers..Iaddend..Iadd.50.  A ridge cover for roofing, said ridge cover being formed of sheet inorganic asphaltic composition roofing material which is back folded on itself to provide an increased thickness and an appearance of thickness for the ridge cover as installed on a roof, said ridge cover comprising: a sheet of flexible inorganic asphaltic composition roofing material which is substantially uniform through its thickness, said sheet including a sheet-like base of felted inorganic fibers through impregnated with a modified asphaltic matrix material, said modified asphaltic matrix material including asphalt and a flexibility improving additive which is present at a weight percentage of at least about three percent, and;   said sheet of inorganic asphaltic composite roofing material being back folded on itself to form a thickening in said ridge cover, and said modified asphaltic matrix material distributing folding stresses within said back fold so as to substantially reduce fracturing of said inorganic fibers of said sheet-like base..Iaddend..Iadd.51. As an article of manufacture, a ridge cover for roofing which at an intermediate stage of manufacture comprises an elongate trapezoidally-shaped sheet of composition roofing material, said roofing material sheet including a base sheet with a sheet-like felt of inorganic fibers in a matrix of modified asphaltic material and being materially uniform throughout its thickness, said modified asphaltic material including asphalt and a flexibility improving additive which is present at a weight percentage of at least about three percent..Iaddend..Iadd.52. The article of manufacture of claim 53 wherein said flexibility improving additive is selected from the group consisting of: styrene-butadiene-styrene and atactic polypropylene..Iaddend..Iadd.53. As an article of manufacture, a ridge cover for roofing which at an intermediate stage of manufacture comprises an elongate trapezoidally-shaped sheet of composition roofing material, said roofing material sheet including a base sheet with a sheet-like felt of inorganic fibers in a matrix of modified asphaltic material and being materially uniform throughout its thickness, said modified asphaltic material including asphalt and a flexibility improving additive;   wherein said flexibility improving additive is added to said asphalt at a weight percentage of from about three percent to about ten percent..Iaddend..Iadd.54. The article of manufacture of claim 53 wherein said article includes a T-shaped longitudinal slit having a cross bar portion disposed toward a narrower end of said trapezoidal shape..Iaddend..Iadd.55. In a ridge cover for roofing which comprises a back folded sheet of composition roofing material, the improvement wherein said material comprises a sheet of felted inorganic fibers through impregnated with a modified asphaltic material including a flexibility improving additive which is present at a weight percentage of at least about three percent..Iaddend.