US20020011043A1 - Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof - Google Patents
Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof Download PDFInfo
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- US20020011043A1 US20020011043A1 US09/253,280 US25328099A US2002011043A1 US 20020011043 A1 US20020011043 A1 US 20020011043A1 US 25328099 A US25328099 A US 25328099A US 2002011043 A1 US2002011043 A1 US 2002011043A1
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- United States
- Prior art keywords
- shingle
- back member
- ridge
- hip
- rigid back
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
- E04D13/002—Provisions for preventing vegetational growth, e.g. fungi, algae or moss
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D2001/005—Roof covering by making use of tiles, slates, shingles, or other small roofing elements the roofing elements having a granulated surface
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
- E04D2001/304—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles at roof intersections, e.g. valley tiles, ridge tiles
- E04D2001/305—Ridge or hip tiles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S52/00—Static structures, e.g. buildings
- Y10S52/09—Structure including reclaimed component, e.g. trash
Abstract
There is provided a hip, ridge, or rake shingle, which includes a shingle panel and at least one rigid back member. The shingle panel has a substantially planar lower surface. The at least one rigid back member has a length substantially the same as or greater than the length of the shingle panel. The rigid back member is attached to the substantially planar lower surface of the shingle panel. The rigid back member includes a step in thickness in a cross-sectional plane perpendicular to the substantially planar lower surface and parallel to the longitudinal axis of the rigid back member. In addition, the thickness of the rigid back member at the high level of the step is greater than the thickness of the rigid back member at one of its ends. There is also provided an asphaltic adhesive including from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.
Description
- The present invention relates generally to the construction of a shingle for covering the hip, ridge, or rake portion of a roof. In particular, the present invention relates to the construction of a hip, ridge, or rake shingle having a thick, aesthetic appearance and a self-aligning mechanism for the rapid and uniform installation of a number of such shingles.
- In the roofing art, it is well-known to attempt to enhance the appearance of a non-wood hip, ridge, or rake shingle by increasing the height of such a shingle to simulate the height of a wood shingle. Examples of such shingles are provided in U.S. Pat. Nos. 5,471,801; 5,377,459; 5,247,771; and 3,913,294. In addition, another example of such a shingle is provided by the Z-Ridge® shingle product sold by Elk Corporation of Ennis, Tex. These shingles are constructed using creative folding designs for the shingle web material to create an overall shingle appearance that is thicker than that of the web material alone.
- While these shingles provide an improved appearance over unfolded or flat shingles, they all suffer from common deficiencies. First, all of the shingles are difficult to align while installing and, thus, require great care in installation to avoid unsightly irregular appearances. Second, when installed, the shingles produce an exaggerated “saw-tooth” appearance, which is different than the more level appearance of wood shingles. Third, the shingles are difficult (if not impossible, in some cases) to install over “ridge vent” products (to be discussed below). Moreover, even in the best case, installation is a two-step process: the “ridge vent” products are nailed in place, followed by the installation of the ridge shingles. Finally, with time and heat, the folds in the shingles tend to compress and the shingles tend to droop and lose their wood-like appearance.
- It is an object of the present invention to provide a hip, ridge, or rake shingle that overcomes these deficiencies.
- According to the present invention, there is provided a hip, ridge, or rake shingle, which includes a shingle panel and at least one rigid back member. The shingle panel has a substantially planar lower surface and an upper surface. The back member has a length that is substantially the same as or greater than the length of the shingle panel. The back member is attached to the substantially planar lower surface of the shingle panel. The back member includes a step in thickness in a cross-sectional plane perpendicular to the substantially planar lower surface and parallel to the longitudinal axis of the back member. In addition, the thickness of the back member at the high level of the step is greater than the thickness of the back member at one of its ends.
- Preferably, the shingle panel is composed of an asphalt material and the upper surface of the shingle panel includes a granular material thereon. Preferably, the composition of the shingle panel further includes a rubberized material. The rubberized material is preferably a styrene-butadiene-styrene block copolymer. Preferably, the back member is composed of an injection-molded thermoplastic. Alternatively, the back member may be composed of any rigid material suitable for outdoor exposure, such as molded recycled tire rubber, metal, or wood. If a thermoplastic is used, the back member may include from about 40% to 70% filler by weight.
- Preferably, the back member includes a trapezoid-shaped base and a plurality of walls extending from the base. The step in thickness of the back member is provided by a step in the height of the walls in a cross-sectional plane perpendicular to the base and parallel to the longitudinal axis of the back member.
- For installation with “ridge vent” systems (to be discussed below), the back member preferably includes channels formed therein communicating between a side of the back member and an area near the longitudinal center axis of the shingle panel. Preferably, the channels are formed in a zig-zag or herringbone pattern. Through the channels, the shingle according to the present invention is able to vent the air escaping through the ridge vent of the roof to the outside environment.
- In yet another preferred embodiment of the invention, the back member includes a planar base surface that is attached to the substantially planar lower surface of the shingle panel. Opposite the planar base surface, the back member includes a surface inclined with respect to the planar base surface and a surface parallel to the planar base surface. At the juncture between the inclined surface and the parallel surface, there is formed the step in thickness of the back member. In this embodiment, the back member preferably includes cavities formed therein. The cavities lighten the back member, but at the same time do not substantially impair the rigidity of the back member.
- According to another aspect of the present invention, the back member is attached to the shingle panel using a novel asphaltic adhesive. The asphaltic adhesive includes from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.
- The grade of the asphalt cement may be any of the grades specified by the American Society for Testing and Materials in Tables 1 to 3 of Publication D338 1-92, entitled “Standard Specification for Viscosity-Graded Asphalt Cement for Use in Pavement Construction.” A blend of different grades of asphalt cement may be used.
- Preferably, the grade of the asphalt cement is AC-30 or below. In addition, it is preferred that the first thermoplastic is a styrene-butadiene-styrene block copolymer having a butadiene/styrene ratio in the range of about 68/32 to about 84/16, a block polystyrene in the range from about 30% to 32%, and an oil content in the range of from about 4.5 phr to 5.5 phr. It is also preferred that the second thermoplastic is a styrene-isoprene-styrene (SIS) block polymer or a latex having a molecular weight in the range of about 100,000 to about 100 million atomic units. The latex may be of a wide variety, including anionic latex, cationic latex, and a combination thereof. Preferably, the latex comprises a styrene-butadiene rubber polymer having from about 62% to about 70% polymer solids in water, a pH in the range of about 5.25 to about 10.5, and a monomer ratio of butadiene to styrene in the range from about 74/26 to about 78/22.
- Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which:
- FIG. 1 is an isometric view of a shingle according to a preferred embodiment of the present invention;
- FIG. 2 is a bottom plan view of a shingle according to the embodiment of FIG. 1;
- FIG. 3 is a side plan view of a shingle according to the embodiment of FIG. 1;
- FIG. 4 is a top plan view of a back member of a shingle according to the embodiment of FIG. 1;
- FIGS. 5 and 6 are side plan views of a shingle according to the embodiment of FIG. 1;
- FIG. 7 is an isometric view of the placement of a series of shingles after installation, each shingle constructed according to the embodiment of FIGS.1 to 6;
- FIG. 8 is a side plan view of a pair of shingles according to another preferred embodiment of the present invention;
- FIG. 9 is an isometric view of a back member of a shingle according to another preferred embodiment of the present invention;
- FIG. 10 is a bottom plan view of a shingle including a back member according to the embodiment of FIG. 9;
- FIG. 11 is a side plan view of a shingle according to the embodiment of FIG. 10;
- FIG. 12 is an isometric view of a back member according to the embodiment of FIG. 9;
- FIG. 13 is a bottom plan view of a shingle according to another preferred embodiment of the present invention;
- FIG. 14 is a side plan view of a back member of a shingle according to the embodiment of FIG. 13; and
- FIG. 15 is a side plan view of a shingle according to the embodiment of FIG. 13.
- FIG. 1 is an isometric view of a
shingle 5 according to a preferred embodiment of the present invention. Theshingle 5 includes ashingle panel 10 and aback member 20, which is attached to the bottom surface 12 (see FIG. 2) of theshingle panel 10. Theshingle panel 10 may be in the form of any symmetrical shape, such as a rectangle or a trapezoid. As shown in FIGS. 1 and 2, however, theshingle panel 10 is preferably trapezoid shaped because a trapezoid shape has been found to yield the best general appearance when theshingle 5 is installed. - The
shingle panel 10 is composed of an asphalt material. Preferably, to enhance its flexibility and bending strength, theshingle panel 10 is composed of a fiberglass-based SBS-modified asphalt material, where SBS represents a styrene-butadiene-styrene block copolymer. As is well-known in the art, theupper surface 14 of the shingle panel 10 (the surface facing away from the roof when the shingle is installed) contains granular ceramic material embedded therein (not shown). - The
back member 20 may be attached to theshingle panel 10 by any suitable asphaltic adhesive. According to one aspect of the present invention, theback member 20 is preferably attached to theshingle panel 10 by a novel asphaltic adhesive comprising from about 62% to about 99% by weight of an asphalt cement; from about 0.5% to about 15% by weight of a first thermoplastic having a high glass-transition temperature (Tg); and from about 0.5% to about 15% by weight of a second thermoplastic having a low glass-transition temperature (Tg). A preferred range for each of said first and second thermoplastics is from about 1% to about 7% by weight. - As used in this specification and the appended claims, a high glass-transition temperature refers to a glass-transition temperature in the range from about 190° F. to about 260° F. and a low glass-transition temperature refers to a glass-transition temperature in the range from about −55° F. to about 0° F. The glass-transition temperature, as known to those skilled in the art, refers to the temperature above which a polymer exhibits liquid-like properties. Advantageously, by combining a thermoplastic with a high glass-transition temperature and a thermoplastic with a low glass-transition temperature, the asphaltic adhesive of the present invention provides excellent adhesive performance in both high temperatures and low temperatures. Thus, the asphaltic adhesive is suitable for a wide variety of geographic locations, including those locations having wide seasonal temperature variations.
- As used in this specification and the appended claims, asphalt cement refers to vacuum distillation bottoms. The grade of the asphalt cement that may be used in the present invention includes any of the grades specified by the American Society for Testing and Materials (“ASTM”in Tables 1 to 3 of Publication D3381-92, entitled “Standard Specification for Viscosity-Graded Asphalt Cement for Use in Pavement Construction” which is incorporated herein by reference. A blend of different grades of asphalt cement may also be used. Preferably, the grade of the asphalt cement is AC-30 or below, as defined by the ASTM in Publication D3381-92. The requirements for asphalt cement of grade levels AC-30 and below are given in Table 1.
TABLE 1 Requirements for Asphalt Cement of Grades AC-30 and Below Viscosity Grades Test AC-2.5 AC-5 AC-10 AC-20 AC-30 Viscosity, 140° F. (60° C.),P 250 ± 50 500 ± 100 1000 ± 200 2000 ± 400 3000 ± 600 Viscosity, 275° F. (135° C.), min, cSt 125 176 250 300 350 Penetration, 77° F. (25° C.), 100 g, 5s, min 220 140 80 60 50 Flash point, Cleveland open cup, min, ° F. (° C.) 325 (163) 350 (177) 425 (219) 450 (232) 450 (232) Solubility in trichloroethylene, min, % 99.0 99.0 99.0 99.0 99.0 Tests on residue from thin-film oven heat: Viscosity, 140° F. (60° C.), max, P 1250 2500 5000 10000 150000 Ductility, 77° F. (25° C.), 5 cm/min, min, cm 100a 100 75 50 40 - The thermoplastic having a low glass-transition temperature may be a latex. The latex may be of a wide variety, including anionic latex, cationic latex, and a combination thereof, having a molecular weight in the range from about 100,000 to about 100 million atomic units. Examples of latex that may be used in the asphaltic adhesive of the present invention include butyl rubber latex, styrene-butadiene rubber latex, neoprene latex, polyvinyl alcohol emulsion latex, water-based polyurethane emulsion latex, water-based polyurethane elastomer latex, vinyl chloride copolymer latex, nitrile rubber latex, or polyvinyl acetate copolymer latex.
- Preferably, the latex is a high molecular weight, high mooney viscosity styrene-butadiene rubber polymer latex that has the properties specified in Table 2.
TABLE 2 Latex Properties Property Range of Values Total Solids, % by weight 62-70 pH 5.25-10.5 Viscosity (Brookfield), cps 800-1650 Monomer Ratio (Butadiene/Styrene) 74/26-78/22 Pounds/Gallon Ratio 7.7-8.1 - Alternatively, instead of latex, the thermoplastic with the low glass-transition temperature may be a linear styrene-isoprene-styrene (SIS) block polymer, such as KRATON® D1107 thermoplastic, which is manufactured and sold by Shell Chemicals Ltd.
- Preferably, the thermoplastic with a high glass-transition temperature is a styrene-butadiene-styrene (SBS) block copolymer having the properties specified in Table 3. The methods referred to in the last column of Table 3 are methods published by the American Society for Testing and Materials. Examples of SBS thermoplastics that be may used for the thermoplastic with the high glass-transition temperature include thermoplastics sold under the brand names KRATON® D1101 (manufactured and sold by Shell Chemicals Ltd.), FINA 409 (manufactured and sold by Fina Oil and Chemical Co.), and FINA 411 (manufactured and sold by Fina Oil and Chemical Co.).
TABLE 3 Styrene-Butadiene-Styrene (SBS) Properties Property Range of Values Method Melt Flow at 180° C./5 kg(g/10 min) 0.1-1.0 ASTMD-1238 Tensile Strength (psi) 2300-4600 ASTM D-638 Elongation at break (%) 550-820 ASTM D-638 300% modulus (psi) 240-800 ASTM D-638 Shore A Hardness 71-82 ASTM D-2240 Butadiene/Styrene Ratio 68/32-84/16 Block Polystyrene (%) 30-32 Oil Content (phr) 4.5-5.5 Specific Gravity at 23° C. (g/cm3) 0.92-0.95 Refractive Index 1.44-1.64 Viscosity of 5.2% Toluene 4-20 Solution (cSt) Color White Form Crumb and/or Powder - Table 4 lists specific adhesive formulations in accordance with the present invention. It is noted that the percentages used in Table 4 are by weight of the asphaltic adhesive. These formulations are hot-melt adhesives, which are applied at temperatures of between 300 degrees and 400 degrees F.
TABLE 4 Specific Adhesive Formulations Formulations Compound Manufacturer 1 2 3 4 5 6 7 8 GB AC-20 Golden Bear, 91.7% 90.9% 94.3% 91.7% 92.2% 92.6% 91.7% Bakersfield, CA GB AC-5 Golden Bear, 91.2% Bakersfield, CA UP-70 Latex UltraPave, 1.4% 1.4% 1.3% 1.4% 0.9% 1.4% SBR Dalton, GA, (Styrene- La Mirada, butadiene CA Rubber) UP-2897 UltraPave, 1.0% Latex Dalton, GA, La Mirada, CA KRATON Shell 2.8% D1107 Chemicals (Styrene- Ltd. isoprene- styrene) Fina 409 SBS FINA Oil and 6.9% 7.7% 4.7% 5.5% 6.4% 6.5% (Styrene- Chemical Co., butadiene- Carville, LA styrene) Fina 411 SBS FINA Oil and 7.5% 6.9% (Styrene- Chemical Co., butadiene- Carville, LA styrene) - Of the formulations listed in Table 4,
formulations 1, 5, 7, and 8 are preferred based on adhesive performance as determined by a SLUMP test using 15-18 mil thick layers of the adhesive formulations. If cost-effectiveness of the formulations is taken into account, the preferred formulation is formulation 7. If expense is not a factor,formulation 5 is preferred overall because of its performance, ease of processing, ease of blending, and ease of storage. - Table 5 lists certain physical properties of the formulations of Table 4, where experimental data for these formulations was available. The physical properties listed in Table 5 are merely exemplary and are not intended to convey representative values. Indeed, as indicated by the data for two different samples of formulation 1, the properties in Table 5 may vary widely due to the variability in the properties of asphalt cement, even when the asphalt cement is of the same grade and obtained from the same manufacturer. The variation in these properties, however, does not greatly effect the adhesive performance of the formulations.
TABLE 5 Physical Properities of Formulations (Final Blend) Formulations Physical 1 1 Properties (Sample 1) (Sample 2) 2 3 4 5 6 7 8 Viscosities (centipoise) 350° F. 608 560 510 360° F. 1162 1667 1767 380° F. 845 1182 795 400° F. 399 630 907 540 373 315 450° F. 234 218 180 Softening 215 221 231 214 197 208 210 Point (° F.) Penetration 38.2 35.0 31.0 41.0 40.1 (mm) - The mixing procedure for the formulations shown in Table 4 includes, first, heating the asphalt cement in a mixing tank to a temperature of between 325° F. to 375° F. Second, the SBS rubber is added to the asphalt cement, and the blend is mixed for about 45 to 120 minutes, until all of the SBS rubber is swelled and no rubber particles are observable. Next, the latex or the SIS thermoplastic material is added to the blend at a temperature of 350° F. If latex is added, caution should be used in adding the latex because the temperature of the blend will cause the water in the latex to evaporate or bubble out. Moreover, latex should be added very slowly to the hot blend as adding the latex too rapidly could splash the blend or could allow the blend to climb up on the mixing stirrer. On complete addition of the latex, the blend is mixed for about 30 minutes. The blend is then ready to use.
- The mixing procedure has been described with reference to a mixing tank. Alternatively, instead of a tank, the mixing may also be performed by injecting the materials through in-line piping, as is well-known by those skilled in the art.
- Cross-linking agents, from about 0.1% to about 2.5% by weight, may also be added to the formulations in Table 4. A preferred range for the cross-linking agents is 0.1% to 0.2% by weight. The addition of cross-linking agents allows less SBS to be used in each formulation; however, it also degrades the low-temperature performance of the asphaltic adhesive.
- If cross-linking agents are to be added to the blend, the cross-linking agents are added after the latex or the SIS thermoplastic material is mixed in. After adding the cross-linking agents, the blend is mixed for about four hours at a temperature of 350° F. to 380° F. Examples of suitable cross-linking agents that may be used in the present invention include the agents sold under the brand names BUTAPHALT 720 (sold by Texpar Energy, Inc., Waukesha, Wis.), HVA-2 (sold by E.I. du Pont de Nemours and Company, Wilmington, Del.), and TETRONE (sold by E.I. du Pont de Nemours and Company, Wilmington, Del.).
- If latex is used in the asphaltic adhesive, it is noted that water will evaporate out of the latex over time and the polymers in the latex may cross-link with each other. Accordingly, if the asphaltic adhesive includes latex, the asphaltic adhesive will become thicker and more viscous over time.
- The
back member 20 is preferably manufactured from an injection-molded thermoplastic material, such as injected-molded polystyrene, polypropylene, or polyethylene. The polystyrene, polypropylene, or polyethylene materials may be low, medium, or high density and may be used with 40% to 70% filler by weight. Such filler may include limestone, gypsum, aluminum trihydrate (ATH), cellulose fiber, and plastic polymer fiber. Other thermoplastic materials that may be used include ethylene-vinyl-acetate (EVA) polymer materials, ethylene-mythylene-acrylate (EMAC) materials, neoprene materials, and polychlorosulfonated polymer (Hypalon) materials. - Although an injection-molded thermoplastic material is preferred for the manufacture of the
back member 20, any rigid material suitable for outdoor exposure is also suitable. For example, molded recycled tire rubber, metal, or wood may also be used. If rubber is used, it is preferred that amine be added to each of the adhesive formulations in Table 4. Up to 5% amine by weight may be added, but because amine's odor is unpleasant, the addition of 0.1% to 0.2% amine by weight is preferred. - FIG. 2 is a bottom plan view of the
shingle 5 of FIG. 1. As shown in FIG. 2, thebase 25 of theback member 20 is also trapezoid-shaped, having substantially the same length as theshingle panel 10. For example, if theshingle panel 10 has a length of 13¼ inches, the back member may be 13 inches long. Theback member 20 is attached to theshingle panel 10 such that the longitudinal center axis 11 of theshingle panel 10 and the longitudinal center axis 21 of the base 25 are aligned. In addition, the short edge 13 of theshingle panel 10 and theshort edge 23 of the base 25 are also aligned. For the purposes of this specification, the end of theshingle 5 including the short edges of theshingle panel 10 andbase 25 will be referred to as the trailing end, and the opposite end of theshingle 5 will be referred to as the front end. - The
back member 20 has two side walls 22 a and 22 b extending from thebase 25 along the base's longitudinal edges. Theback member 20 also has eightlongitudinal walls 24 extending from thebase 25, which are parallel to the longitudinal axis 21 of thebase 25, and eight transverse walls 26 a-26h extending from thebase 25, which are perpendicular to the longitudinal axis 21 of thebase 25. Two of thetransverse walls 26 a and 26 e are disposed along the front edges of thebase 25. - The transverse walls26 a-26 h are divided into two sets of four walls, which are disposed on opposite sides of the longitudinal center axis 21 of the
base 25. The first set includes walls 26 a-26 d, and the second set includes walls 26 e-26h. In addition,wall 26 a is disposed opposite wall 26 e; wall 26 b is disposedopposite wall 26 f; wall 26 c is disposed opposite wall 26g and wall 26 d is disposedopposite wall 26 h. The opposing walls are offset from each other along the longitudinal center axis 21 by an amount ΔA sufficient to ensure that they do not interfere with each other when theshingle 5 is folded—i.e., they are offset from each other by an amount greater than the width of each wall. To facilitate the folding of theshingle 5, theback member 20 preferably has aslit 27 in thebase 25 along its longitudinal center axis 21. The base 25 also has rectangular holes 28 in the areas between some of thelongitudinal walls 24 and the transverse walls 26 a-26 h. The holes 28 limit the twists and deformation of thebase 25 under heat. - FIG. 3 is a side plan view of the
shingle 5 of FIG. 1, viewed along an axis perpendicular to the longitudinal center axis 11 of theshingle panel 10. As shown in FIG. 3, the side wall 22 a of theback member 20 is composed of a wedge-shaped section 29 aand a rectangular section 29 b. Transverse wall 26 b is positioned at the juncture betweensections 29 a and 29 b. At the juncture of the wedge-shapedsection 29 a and rectangular section 29 b, there is a step in the height of the side wall 22 a—i.e., the height of the wedge-shapedsection 29 a is greater than the height of section 29 b. - Side wall22 b is identical to sidewall 22 a. At any point along the longitudinal axis of the
back member 20, the height of each of thelongitudinal walls 24 and the transverse walls 26 a-26 h corresponds to the height of the sidewalls 22 a and 22 b at that longitudinal position. - FIG. 4 is a top plan view of the
back member 20. The top surface of thebase 25 is preferably corrugated, with the corrugations running longitudinally along thebase 25. The corrugations facilitate the adherence of theback member 20 to theshingle panel 10. FIGS. 5 and 6 are side plan views of theback member 20 viewed along axes parallel to the longitudinal center axis 21 of theback member 20. FIGS. 5 and 6 further illustrate the features of theback member 20 discussed above. - FIG. 7 is an isometric view of the placement of a series of shingles5 a, 5 b, and 5 c after installation on a hip, ridge, or rake portion of a roof. Each of the shingles 5 a, 5 b, and 5 c is a shingle according to the embodiment of FIGS. 1 to 6, with the
shingle panel 10 folded along its longitudinal center axis 11 (see FIG. 2) to form an inverted V-shape with theback member 20 inside of theshingle panel 10. To begin the installation, shingle 5 a is placed on the hip, ridge, or rake portion of the roof and installed by nailing or other suitable means. Shingle 5 b is then placed on top of shingle 5 a, with the front end of shingle 5 b placed on the trailing end of shingle 5 a. The front end of shingle 5 b is then slid toward the front end of shingle 5 a until the step of theback member 20 of shingle 5 b engages the edges at the trailing end of shingle 5 a. Shingle 5 b is then nailed or otherwise suitably fastened in place on the roof. Shingle 5 c is installed in the same manner over shingle 5 b. - As will be appreciated by those skilled in the art, shingles according to the present invention provide the following benefits. First, the step of the
back member 20 allows the shingles to be easily aligned with each other for a quick and uniform installation. Second, the thickness of theback member 20 enhances the appearance of the shingles and provides a wood-like look to the shingles. Third, since theback member 20 is substantially the same length as theshingle panel 10, the thickness of each shingle is enhanced across its entire length, and the shingles thereby avoid an exaggerated “saw-tooth” appearance after installation. Finally, since theback member 20 of each shingle is made of a rigid material, the shingles will not droop over time or under heat and lose their thick, wood-like appearance. - FIG. 8 is a side plan view of a pair of shingles100 a and 100 b according to another preferred embodiment of the present invention. Each of the shingles 100 a and 100 b includes a
shingle panel 110 and aback member 120 similar to theshingle panel 10 and backmember 20, respectively, of FIGS. 1 to 6. A difference between theback member 120 of FIG. 8 and theback member 20 of FIGS. 1 to 6 is that the step of theback member 120 is angled so that when the shingles 100 a and 100 b are installed, the shingles 100 a and 100 b interlock with one another. - FIGS.9 to 12 illustrate a
shingle 200 according to another preferred embodiment of the present invention, which incorporates a ventilation function for “ridge vent” systems. Presently, many homes are constructed such that the peak of a roof has an opening of approximately two inches along its length. This opening is covered by a special “ridge vent” material that allows air to pass out of the home, but prevents insects and moisture from entering into the home. The “ridge vent” material is then covered by standard ridge shingle products. Clearly, a two-step process is currently necessary for the installation of shingles on homes using a “ridge vent” system. - FIG. 9 is an isometric view of a
back member 220 according to a preferred embodiment of the present invention, and FIG. 10 is a bottom plan view of theback member 220. As in the previous embodiments, theback member 220 includes a trapezoid-shapedbase 225. Thebase 225 includes aslit 227 along itslongitudinal center axis 221 to facilitate the folding of theback member 220. - Six
transverse walls 226 a-226 f extend from thebase 225 and run in a direction perpendicular to thelongitudinal center axis 221 of thebase 225. Thetransverse walls 226 a-226 f are divided into two sets of three walls, which are disposed on opposite sides of thelongitudinal center axis 221. The first set includeswalls 226 a-226 c, and the second set includeswalls 226 d-226 f. In addition, wall 226 a is disposedopposite wall 226 d; wall 226 b is disposed opposite wall 226 e; and wall 226 c is disposedopposite wall 226 f. The opposing walls are offset from each other along thelongitudinal center axis 221 by an amount ΔA sufficient to ensure that they do not interfere with each other when theshingle 200 is folded—i.e., they are offset from each other by an amount greater than the width of each wall. - Between the trailing edge of the
base 225 and thetransverse walls 226 c and 226 f, fourwalls 224 parallel to thelongitudinal center axis 221 of theback member 220 extend from thebase 225. In addition, in this area, there are disposed twoside walls 222 extending from the longitudinal edges of thebase 225. - Between the transverse walls226 a and 226 c and the
transverse walls channel walls 230 extending from thebase 225. Thechannel walls 230 are preferably arranged in a zig-zag or herringbone pattern and form channels communicating between the sides of theback member 220 and the central portion of the back member 220 (the area around thelongitudinal center axis 221 of the back member 220). In addition, along the longitudinal edges of thebase 225, there aredisposed pins 232 extending from thebase 225. Preferably, thepins 232 are spaced apart so that the width of each of the openings along the sides of theback member 225 is less than ¼ inch. - When a
shingle 200 withback member 220 is placed on a ridge vent roof, the air being vented from the ridge of the roof passes through the channels formed by thechannel walls 230 and into the outside environment. Advantageously, the zig-zag or herringbone pattern of thechannel walls 230 prevents the entry of water into the ridge vent by forcing the water to take a tortuous path through theback member 220. In addition, thepins 232 prevent the penetration of insects into theback member 220 by restricting the width of the openings in the sides of theback member 220. Accordingly, the installation of ridge vent material underneath theshingle 200 is not necessary, and only a one-step installation process is necessary to install shingles according to this embodiment on a ridge vent roof. - FIG. 11 is a side plan view of the
back member 220, showing theback member 220 includes the same step feature as theback member 20 of FIGS. 1 to 6. Dividing theback member 220 into two sections 229 a and 229 b for the purposes of discussion (with the transverse wall 226 e serving as the partition between the two sections), the walls in section 229 a increase in height along the longitudinal axis of theback member 220 from the trailing edge of the base 225 to the transverse wall 226 e. In section 229 b, all of the walls have the same height, which is less than that of the transverse wall 226 e. The difference in height between the walls in section 229 a and the walls in section 229 b provides the step in thickness of theback member 220. - FIG. 12 is an isometric view of the
back member 220. The top surface of thebase 225 is preferably corrugated, with the corrugations running longitudinally along thebase 225. The corrugations facilitate the adherence of theback member 220 to theshingle panel 210. - As shown in FIGS. 9, 10, and12, between the trailing edge of the
base 225 and thetransverse walls 226 c and 226 f, there are disposed a plurality ofcircular holes 228 in thebase 225. If theshingle panel 210 is made shorter than the base 225 (not shown), theholes 228 provide a further of means of ventilation for the air escaping the ridge vent of the roof. - FIG. 13 is a bottom plan view of a
shingle 300 according to another preferred embodiment of the present invention. Theshingle 300 includes ashingle panel 310 having attached thereto twoback members 320 a and 320 b. Theback members 320 a and 320 b are mirror images of each other and are placed on theshingle panel 310 in symmetrical relation with respect to thelongitudinal center axis 311 of theshingle panel 310. - FIG. 14 is a side plan view of
back member 320 a, viewed from an axis perpendicular to thelongitudinal center axis 311 of theshingle panel 310. (The corresponding side plan view of back member 320 b is the same.) The back member 320 aincludes a planar base surface 325 a, which is attached to theshingle panel 310. Opposite the planar base surface 325 a, the back member has aplanar surface 324 a that is inclined with respect to the base surface 325 a and aplanar surface 326 a that is parallel to the base surface 325 a. At the juncture between thesurfaces surface 324 a is greater than the height ofsurface 326 a, thereby producing a step in the thickness of theback member 320 a. Theback members 320 a and 320 b preferably include a plurality of rectangular-shapedcavities 328 a and 328 b therein, respectively, which lighten the back members and reduce the material needed to construct them. - FIG. 15 is a side plan view of
shingle 300, viewed from the front end along an axis parallel to thelongitudinal center axis 311 of theshingle panel 310. Theback member 320 a hasside walls back member 320 a and 320 b are angled inwardly with respect to eachback member 320 a and 320 b. The angling ofside walls 322 a and 322 b is necessary to ensure that these side walls do not interfere with each other when theshingle panel 310 is folded. - Although the present invention has been described with reference to certain preferred embodiments, various modifications, alterations, and substitutions will be apparent to those skilled in the art without departing from the spirit and scope of the invention, as defined by the appended claims.
Claims (34)
1. A hip, ridge, or rake shingle comprising:
a shingle panel having a substantially planar lower surface and an upper surface; and
at least one rigid back member having a length substantially the same as or greater than the length of said shingle panel and attached to said substantially planar lower surface of said shingle panel, said at least one rigid back member having a step in thickness in a cross-sectional plane perpendicular to said substantially planar lower surface and parallel to the longitudinal axis of said at least one rigid back member, the thickness of said at least one rigid back member at the high level of said step being greater than the thickness of said at least one rigid back member at an end of said at least one rigid back member.
2. The hip, ridge, or rake shingle of claim 1 , wherein said shingle panel is composed of an asphalt material and said upper surface of said shingle panel includes a granular material thereon.
3. The hip, ridge, or rake shingle of claim 2 , wherein said shingle panel further comprises a rubberized material.
4. The hip, ridge, or rake shingle of claim 3 , wherein said rubberized material is a styrene-butadiene-styrene block copolymer.
5. The hip, ridge, or rake shingle of claim 1 , wherein said at least one rigid back member includes a trapezoid-shaped base and a plurality of walls extending from said base, said walls having a step in height in a cross-sectional plane perpendicular to said base and parallel to the longitudinal axis of said at least one rigid back member, said step in height of said walls providing said step in thickness of said at least one rigid back member.
6. The hip, ridge, or rake shingle of claim 5 , wherein said plurality of walls includes first and second sets of walls disposed on opposite sides of and perpendicular to the longitudinal center axis of said at least one rigid back member.
7. The hip, ridge, or rake shingle of claim 6 , wherein each wall in said first set of walls and a corresponding wall in said second set of walls are offset from each other along the longitudinal center axis of said at least one rigid back member by an amount greater than the width of each wall.
8. The hip, ridge, or rake shingle of claim 5 , wherein said base includes corrugations on the surface to be attached to said substantially planar lower surface of said shingle panel.
9. The hip, ridge, or rake shingle of claim 5 , wherein said base includes a slit along its longitudinal center axis for facilitation of folding of said at least one rigid back member.
10. The hip, ridge, or rake shingle of claim 1 , wherein said step is capable of interlocking with an end of a shingle which is substantially identical to said hip, ridge, or rake shingle.
11. The hip, ridge, or rake shingle of claim 1 , wherein said at least one rigid back member includes channels formed therein communicating between a side of said at least one rigid back member and an area near the longitudinal center axis of said shingle panel, whereby when said shingle is installed on a ridge vent roof, said channels allow ventilation of the roof to the outside environment.
12. The hip, ridge, or rake shingle of claim 11 , wherein said channels are arranged in a zig-zag or herringbone pattern.
13. The hip, ridge, or rake shingle of claim 11 , wherein the width of the openings of said channels along the sides of said at least one rigid back member is less than or equal to ¼ inch.
14. The hip, ridge, or rake shingle of claim 11 , wherein said at least one rigid back member includes a trapezoid-shaped base and a plurality of walls extending from said base, said plurality of walls forming said channels.
15. The hip, ridge, or rake shingle of claim 14 , wherein said at least one rigid back member includes a plurality of pins extending from the longitudinal edges of said base.
16. The hip, ridge, or rake shingle of claim 1 , wherein said at least one rigid back member includes a planar base surface that is attached to said substantially planar lower surface of said shingle panel, a surface inclined with respect to said planar base surface, and a surface parallel to said planar base surface; and wherein said step in thickness of said at least one rigid back member is formed at the juncture of said inclined surface and said parallel surface.
17. The hip, ridge, or rake shingle of claim 16 , wherein said at least one rigid back member includes cavities formed therein.
18. The hip, ridge, or rake shingle of claim 1 , wherein said at least one rigid back member is composed of an injection-molded thermoplastic material.
19. The hip, ridge, or rake shingle of claim 18 , wherein said thermoplastic material is selected from the group consisting essentially of polystyrene, polypropylene, polyethylene, ethylene-vinyl-acetate (EVA), ethylene-mythylene-acrylate (EMAC), neoprene, and polychlorosulfonated polymer (Hypalon).
20. The hip, ridge, or rake shingle of claim 19 , wherein said at least one rigid back member further includes from about 40% to about 70% filler by weight.
21. The hip, ridge, or rake shingle of claim 20 , wherein said filler is selected from the group consisting essentially of limestone, gypsum, aluminum trihydrate, cellulose fiber, and plastic polymers fiber.
22. The hip, ridge, or rake shingle of claim 1 , wherein said at least one rigid back member is composed of a material selected from the group consisting essentially of molded recycled tire rubber, metal, and wood.
23. An asphaltic adhesive for use with roofing material, comprising:
from about 62% to about 99% by weight of an asphalt cement;
from about 0.5% to about 15% by weight of a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and
from about 0.5% to about 15% by weight of a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.
24. The asphaltic adhesive of claim 23 , comprising from about 1% to about 7% by weight of said first thermoplastic and from about 1% to about 7% by weight of said second thermoplastic.
25. The asphaltic adhesive of claim 23 , wherein said first thermoplastic is a styrene-butadiene-styrene block copolymer.
26. The asphaltic adhesive of claim 25 , wherein said styrene-butadiene-styrene block copolymer has a butadiene/styrene ratio in the range of about 68/32 to about 84/16, a block polystyrene in the range from about 30% to 32%, and an oil content in the range of from about 4.5 phr to 5.5 phr.
27. The asphaltic adhesive of claim 23 , wherein said second thermoplastic is a styrene-isoprene-styrene block polymer.
28. The asphaltic adhesive of claim 23 , wherein said second thermoplastic is a latex having a molecular weight in the range of about 100,000 to about 100 million atomic units.
29. The asphaltic adhesive of claim 28 , wherein said latex comprises a styrene-butadiene rubber polymer.
30. The asphaltic adhesive of claim 29 , wherein said styrene-butadiene rubber polymer comprises from about 62% to about 70% polymer solids in water, has a pH in the range of about 5.25 to about 10.5, and has a monomer ratio of butadiene to styrene in the range from about 74/26 to about 78/22.
31. The asphaltic adhesive of claim 23 , wherein the grade of said asphalt cement is AC-30 or below.
32. The asphaltic adhesive of claim 23 , further comprising from about 0.1% to about 2.5% by weight of one or more cross-linking agents.
33. The asphaltic adhesive of claim 23 , further comprising from about 0.1% to 5.0% by weight of amine.
34. A method of producing an asphaltic adhesive, comprising the steps of:
heating an asphalt cement to a temperature of between 325° F. to 375° F.;
mixing into said asphalt cement a first thermoplastic having a glass-transition temperature in the range from about 190° F. to about 260° F.; and
mixing into the blend of said asphalt cement and said first thermoplastic a second thermoplastic having a glass-transition temperature in the range from about −55° F. to about 0° F.; wherein said blend of asphalt cement, first thermoplastic, and second thermoplastic comprises from about 62% to about 99% by weight of said asphalt cement; from about 0.5% to about 15% by weight of said first thermoplastic; and from about 0.5% to about 15% by weight of said second thermoplastic.
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US09/253,280 US20020011043A1 (en) | 1999-02-19 | 1999-02-19 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
US09/849,732 US6530189B2 (en) | 1999-02-19 | 2001-05-04 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
US10/008,865 US6418692B1 (en) | 1999-02-19 | 2001-12-06 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
US10/034,179 US20020057417A1 (en) | 1999-02-19 | 2001-12-26 | Polysaccharide coating of contact lenses |
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US09/253,280 US20020011043A1 (en) | 1999-02-19 | 1999-02-19 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
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US10/034,179 Continuation US20020057417A1 (en) | 1999-02-19 | 2001-12-26 | Polysaccharide coating of contact lenses |
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US10/008,865 Expired - Lifetime US6418692B1 (en) | 1999-02-19 | 2001-12-06 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
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US10/008,865 Expired - Lifetime US6418692B1 (en) | 1999-02-19 | 2001-12-06 | Aesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof |
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US5305569A (en) | 1989-04-19 | 1994-04-26 | Elk Corporation Of Dallas | Thick shingle |
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US5377459A (en) | 1991-04-09 | 1995-01-03 | Freiborg; Bennie | Ridge cover and shingle and method of making and using the same |
US5369929A (en) | 1991-09-18 | 1994-12-06 | Elk Corporation Of Dallas | Laminated roofing shingle |
US5247771A (en) | 1992-03-23 | 1993-09-28 | Poplin James E | Ridge shingle unit |
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GB9217797D0 (en) * | 1992-08-21 | 1992-10-07 | Forticrete Ltd | Novel building element |
CA2113021A1 (en) * | 1993-01-28 | 1994-07-29 | Richard J. Macleod | Roof vent |
US5295340A (en) | 1993-04-05 | 1994-03-22 | Pacific Coast Building Products, Inc. | Dimensional shingle for hip, ridge and rake portions of a roof |
US5365711A (en) | 1993-04-28 | 1994-11-22 | Pressutti Joseph E | Low-cost highly aesthetic and durable shingle |
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US5676597A (en) | 1995-07-27 | 1997-10-14 | Building Materials Corporation Of America | Vented hip, ridge and rake composite shingle |
US5711126A (en) | 1996-05-13 | 1998-01-27 | Owens-Corning Fiberglass Technology, Inc. | Resinous angled shingles for roof ridge lines |
US6012611A (en) | 1996-06-14 | 2000-01-11 | The Coca-Cola Company | Bag-in-box box and method |
CA2228639A1 (en) * | 1997-02-04 | 1998-08-04 | Mark Freiborg | Asphalt composition ridge covers with three dimensional effect |
US6148578A (en) | 1998-06-17 | 2000-11-21 | Nowacek; David C. | Slate and interlayment roof and a method of preparing the same |
-
1999
- 1999-02-19 US US09/253,280 patent/US20020011043A1/en not_active Abandoned
-
2001
- 2001-05-04 US US09/849,732 patent/US6530189B2/en not_active Expired - Lifetime
- 2001-12-06 US US10/008,865 patent/US6418692B1/en not_active Expired - Lifetime
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US20060214336A1 (en) * | 2003-12-16 | 2006-09-28 | Kim Joong Y | Composite building product |
US8257811B2 (en) * | 2003-12-16 | 2012-09-04 | Certainteed Corporation | Composite building product |
US7851051B2 (en) | 2005-02-08 | 2010-12-14 | Elk Premium Building Products, Inc. | Roofing material |
US20060185298A1 (en) * | 2005-02-08 | 2006-08-24 | Dejarnette Daniel C | Roofing material |
US20060265989A1 (en) * | 2005-05-24 | 2006-11-30 | Geary David A | Self-Aligning Roofing Shingles |
US20070022671A1 (en) * | 2005-07-28 | 2007-02-01 | Plemmons Harold F | Weather resistant structure |
US20080034705A1 (en) * | 2006-08-02 | 2008-02-14 | Andrew Truss | Stacking bar for roofing elements |
US20090100779A1 (en) * | 2007-10-23 | 2009-04-23 | Duron Plastics Limited | Plastic roof shingle |
US8707643B1 (en) | 2007-11-08 | 2014-04-29 | Certainteed Corporation | Roofing element and roof covering comprised thereof |
GB2467000A (en) * | 2009-01-19 | 2010-07-21 | Sandtoft Roof Tiles Ltd | Roof tile with different edge thicknesses and lengths |
US20150047285A1 (en) * | 2013-08-15 | 2015-02-19 | Building Materials Investment Corporation | Shingle with transition device for impact resistance |
US9010058B2 (en) * | 2013-08-15 | 2015-04-21 | Building Materials Investment Corporation | Shingle with transition device for impact resistance |
US9853595B1 (en) * | 2016-08-18 | 2017-12-26 | Yanegijutsukenkyujo Co., Ltd. | Fixture for on-roof installation object and fixing structure of on-roof installation object |
US20200048909A1 (en) * | 2018-08-10 | 2020-02-13 | Mohawk Carpet Llc | Roof ridge or hip covering element and method for manufacturing a roof ridge or hip covering element |
US10941572B2 (en) * | 2018-08-10 | 2021-03-09 | Daltile Corporation | Roof ridge or hip covering element and method for manufacturing a roof ridge or hip covering element |
US11549265B2 (en) | 2018-08-10 | 2023-01-10 | Dal-Tile Corporation | Roof ridge or hip covering element and method for manufacturing a roof ridge or hip covering element |
US11105097B2 (en) * | 2019-12-19 | 2021-08-31 | Eraserspacer Llc | Roofing panel for concealing a biocidal source |
US20210355684A1 (en) * | 2019-12-19 | 2021-11-18 | Eraserspacer Llc | Roofing panel for concealing a biocidal source |
Also Published As
Publication number | Publication date |
---|---|
US20020078651A1 (en) | 2002-06-27 |
US6418692B1 (en) | 2002-07-16 |
US6530189B2 (en) | 2003-03-11 |
US20020038531A1 (en) | 2002-04-04 |
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Legal Events
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AS | Assignment |
Owner name: ELK CORPORATION OF DALLAS, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FRESHWATER, JOHN G.;HUDSON, WILLARD CALVIN, JR.;MAYTUBBY, CLARK DANIEL;AND OTHERS;REEL/FRAME:009854/0431;SIGNING DATES FROM 19990310 TO 19990319 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO PAY ISSUE FEE |