Roofing shingles and roofing method

A roofing shingle (20) comprises a web (22) of roofing material configured with a first series of sealant material sites (60) and a second series of sealant material sites (62) provided on the roofing shingle (20). The web (22) of roofing material is configured with a length dimension (L) and a width dimension (W). The sealant material sites 60 of the first series are provided along a first axis (66) which is essentially parallel to the length dimension of the web. The sealant material sites (60) of the first series are discontinuous along the first axis (66) and separated from one another along the first axis by a first interval (70). The sealant material sites of the second series (62) are provided along a second axis (68) which is essentially parallel to the length dimension of the web and spaced apart from the first axis (66) with respect to the width dimension. The sealant material sites (62) of the second series are discontinuous along the second axis (68) and are separated from one another along the second axis (68) by a second interval (72), the second interval (72) being different than the first interval (70).

U.S. Design patent application 29/648,855, filed May 23, 2018, entitled “Roofing Shingle” is incorporated by reference herein in its entirety.

TECHNICAL FIELD

This invention pertains to roofing shingles and methods of affixing roofing shingles to a sloped roof.

BACKGROUND

Roofing shingles are some of the most prevalent forms of roofing materials. Roofing shingles are particularly popular for residential buildings. While shingle appearance and design must be appealing, shingle manufacture and installment should be efficient and economical.

Shingle production typically involves feeding a substrate into a production line. In the production line, hot asphalt is applied to the substrate. Granules are deposited and embedded into the substrate. The granules which are embedded into what will be, upon installation, an exposed portion of the substrate, are often called “finish” granules, and may be of a particular color or combination of colors. Typically less colorful or less esthetically appealing granules are embedded into an un-exposed or headlap portion of the substrate. The granule laden substrate is then cut to a package length, e.g. into a package unit, along a major dimension of the shingle. For many general purpose shingles the package unit has a number of tabs on its lower or exposed surface which are separated by slots which extend in a minor dimension (e.g., height) of the shingle.

Large format shingles have become popular in some markets. An advantage in using large format shingles is that fewer nails are required to secure the shingle to a roof. Examples of large format shingles include, for example, those shown and described in U.S. Pat. Nos. 5,501,056; 5,375,491; 5,421,134; 5,287,669; and United States Patent Publication 2009/0139175.

United States Patent Publication 2009/0139175 also shows an example wherein sealant stripes are provided on a shingle, and wherein the sealant stripes are staggered to form offset channels to facilitate drainage. U.S. Pat. No. 7,204,063 also describes sealant stripes.

The sealant stripes may boarder a nailing zone. Other US patents that refer to a nailing zone or sealant stripes include U.S. Pat. Nos. 6,145,265 and 6,397,546.

What is needed, therefore, and an example object of the technology disclosed herein, is a roofing shingle that is configured to promote both drainage and wind resistance without excessive sealant material, and which is readily installable on a roof with essentially no shingle waste or extensive nailing.

SUMMARY

In one of its example aspects the technology disclosed herein concerns a roofing shingle comprising a web of roofing material configured with a first series of sealant material sites and a second series of sealant material sites provided on the shingle. The web of roofing material is configured with a length dimension and a width dimension. The sealant material sites of the first series are provided along a first axis which is essentially parallel to the length dimension of the web. The sealant material sites of the first series are discontinuous along the first axis and separated from one another along the first axis by a first interval. The sealant material sites of the second series are provided along a second axis which is essentially parallel to the length dimension of the web and are spaced apart from the first axis with respect to the width dimension. The sealant material sites of the second series are discontinuous along the second axis and separated from one another along the second axis by a second interval, the second interval being different than the first interval.

In an example embodiment and mode, the second interval is greater than the first interval,

In an example embodiment and mode, a first edge of the shingle along the length dimension comprises at least one cut-out to form at least one tab. With respect to the width dimension of the shingle, the second series of sealant material sites is farther than the first series of sealant material sites to the first length edge of the shingle. In an example implementation, the shingle further comprises a backing sheet secured to a lower surface of the web, the lower surface of the web being opposite the face of the web. The backing sheet being is with essentially a same length dimension as the web but with a smaller width dimension than the web. A first length edge of the backing sheet is substantially aligned with the first length edge of the shingle and a second length edge of the backing sheet is substantially aligned under the web with at least an edge of the sealant material sites of the second series.

In an example embodiment and mode, at least one cut-out comprises a cut-out length edge that is parallel to the length dimension of the shingle, and a nailing zone distance of a nailing zone in the width dimension from the cut-out length edge to the second series of sealant material sites is substantially 1.5 inches. In an example implementation, with respect to the width dimension of the shingle the nailing zone is substantially six inches from the first length edge of the shingle.

In an example embodiment and mode, a ratio of the length dimension of the shingle to the width dimension of the shingle is 3:1. In an example implementation, a length of the shingle along the length dimension is 42 inches and a width of the shingle along the width dimension is 14 inches. In an example implementation, the length of the second interval is three inches and the length of the first interval is one inch.

In an example embodiment and mode, the sealant material sites of the first series and the second series have a length in the length dimension of substantially 1 inch and a width in the width dimension of substantially ⅜ inch.

In an example embodiment and mode, with respect to the length dimension a first site of the second series of sealant material sites is substantially aligned between neighboring first and second sites of the first series of sealant material sites, and a second site of the second series of sealant material sites which neighbors the first site of the second series of sealant material sites is substantially aligned between neighboring third and fourth sites of the first series of sealant material sites.

In another of its aspects the technology disclosed herein concerns a method of installing roofing shingles on a roof. Each of the shingles comprises a web configured with a length dimension of L=C*I units of measure, L and I being even integers of a measurement unit and C being an odd integer of the measurement unit. The method comprises an act (1) comprising, for a first course of installation, applying an entire shingle to the underlayment of the roof. Act (2) of the method comprises, for each of X=2, . . . J courses of installation, J being an integer: (a) forming from an Xth shingle, in which an Xth shingle major portion having a length L−((X−1)*I) and an Xth shingle minor portion having a length L−L−((X−1)*I; (b) applying the Xth shingle major portion over at least a portion of an X−1th shingle major portion and to the underlayment. Act (3) of the method comprises, for each of Y=J+1, . . . C courses of installation, applying one of the Xth shingle minor portions over at least a portion of course Y−1 and to the underlayment. In the method edges of the shingle major portions and shingle minor portions applied for courses 2−C are substantially aligned in the length dimension with an edge of the entire shingle applied for the first course.

In an example embodiment and mode the measurement unit is inches.

In an example embodiment and mode the web of each shingle is configured with a width W in a width dimension, and wherein W=L/3.

In an example embodiment and mode each shingle comprises a first series of sealant material sites and a second series of sealant material sites provided on the shingle, and a backing sheet. The sealant material sites of the first series is provided along a first axis which is essentially parallel to the length dimension of the web. The sealant material sites of the first series are discontinuous along the first axis and separated from one another along the first axis by a first interval. The sealant material sites of the second series being are along a second axis which is essentially parallel to the length dimension of the web and spaced apart from the first axis with respect to the width dimension. The sealant material sites of the second series are discontinuous along the second axis and separated from one another along the second axis by a second interval. The second interval being different than the first interval. The backing sheet is secured to a lower surface of the web, the lower surface of the web being opposite the face of the web. The backing sheet is configured with essentially a same length dimension as the web but with a smaller width dimension than the web, a first length edge of the backing sheet being aligned with the first length edge of the shingle and a second length edge of the backing sheet being substantially aligned under the web with at least an edge of the sealant material sites of the second series. The at least one cut-out comprises a cut-out length edge that is parallel to the length dimension of the shingle. In this example embodiment and mode the method further comprises applying the shingle major portions and the shingle minor portions of the respective courses comprises nailing the shingle major portions and the shingle minor portions in a nailing zone of the respective shingle major portions and the shingle minor portions. The nailing zone extends substantially 1.5 inches in the width dimension from the cut-out length edge to the second series of sealant material sites.

In another of its example aspects the technology disclosed herein concerns a roofing shingle comprising a web of roofing material configured with a length dimension and a width dimension; and at least a first series of sealant material sites provided on the shingle. The sealant material sites of the first series are provided along a first axis which is essentially parallel to the length dimension of the web. The sealant material sites of the first series being discontinuous along the first axis and separated from one another along the first axis by a first interval. A number of sealant material sites provided on the shingle is equal to or greater than 18. In an example implementation, a ratio of the length dimension of the shingle to the width dimension of the shingle is 3:1; and the length dimension is substantially 42 inches.

In an example embodiment and mode, L=42, C=7, and I=6, and the method further comprises: (i) for the first course of installation, applying the entire first shingle to the underlayment of the roof; (ii) for the second course of installation, removing a 6 inch length of a second shingle and applying a remaining 36 inch portion of the second shingle over a portion of the first shingle and to the underlayment whereby along the length dimension an edge of the first shingle is substantially aligned with an edge of the remaining 36 inch portion of the second shingle; (iii) for the third course of installation, removing a 12 inch length of a third shingle and applying a remaining 30 inch portion of the third shingle over a portion of the 36 inch portion of the second shingle and to the underlayment whereby along the length dimension an edge of the 36 inch portion of the second shingle is substantially aligned with an edge of the remaining 30 inch portion of the third shingle; (iv) for the fourth course of installation, removing an 18 inch length of a fourth shingle and applying a remaining 24 inch portion of the fourth shingle over a portion of the 30 inch portion of the third shingle and to the underlayment whereby along the length dimension an edge of the 30 inch portion of the third shingle is substantially aligned with an edge of the remaining 24 inch portion of the fourth shingle; (v) for the fifth course of installation, applying a removed 18 inch length of shingle over a portion of the 24 inch portion of the fourth shingle and to the underlayment whereby along the length dimension an edge of the 24 inch portion of the fourth shingle is substantially aligned with an edge of the removed 18 inch length of shingle; (vi) for the sixth course of installation, applying a removed 12 inch length of shingle over the removed 18 inch length of shingle and to the underlayment whereby along the length dimension an edge of the removed 18 inch length of shingle is substantially aligned with an edge of the removed 12 inch length of shingle; and, (vii) for the seventh course of installation, applying a removed 6 inch length of shingle over the removed 12 inch length of shingle and to the underlayment whereby along the length dimension an edge of the removed 12 inch length of shingle is substantially aligned with an edge of the removed 6 inch length of shingle. In an example implementation, the removed 18 inch length of shingle is removed from the fourth shingle; the removed 12 inch length of shingle is removed from the third shingle; and the removed 6 inch length of shingle is removed from the second shingle.

In an example embodiment and mode, wherein the method further comprises, after performing acts (1)-(4), applying one or more entire shingles to each of the C courses to abut a shingle, a shingle major portion, or a shingle minor portion already in the respective course; optionally installing further courses according to acts (1)-(4); and wherein 56 shingles are installed per average square with substantially no shingle waste.

DETAILED DESCRIPTION

In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular architectures, interfaces, techniques, etc. in order to provide a thorough understanding of the technology disclosed herein. However, it will be apparent to those skilled in the art that the technology disclosed herein may be practiced in other embodiments that depart from these specific details. That is, those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the technology disclosed herein and are included within its spirit and scope. In some instances, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description of the technology disclosed herein with unnecessary detail.

FIG. 1-FIG. 3show a roofing shingle20which, e.g., as described herein, is configured to provide strong shingle-to-shingle adhesion while also facilitating moisture egression from between shingles, and to provide an installation-friendly nailing zone. As also described herein, the structure and features of the roofing shingle20engender a substantially waste-free shingle installation method which is relatively oblivious to roof slope.

As shown inFIG. 1andFIG. 2, roofing shingle20is essentially rectangular in overall footprint and has length dimension L and width dimension W. In the non-limiting example embodiment and mode ofFIG. 1andFIG. 2, the roofing shingle20comprises a web22of roofing material which comprises an upper surface or web face24. The roofing shingle20and its web22have a first or lower length edge26which, upon installation of the roofing shingle20on a roof, will be lower on the roof than a second or upper length edge27. The roofing shingle20and its face24also have a left width edge28and right width edge29. The first length edge26and second or upper length edge27are essentially parallel with the length dimension L; the left width edge28and right width edge29are essentially parallel with the width dimension W, and thus perpendicular to the first length edge26and second or opposite length edge27.

In a non-limiting example embodiment and mode shown inFIG. 1andFIG. 2, the roofing shingle20is a laminated two-layer shingle, wherein web22serves as a top layer and a backing sheet30serves as a lower layer of the two-layer laminated roofing shingle20. The backing sheet30is secured to a lower surface31of the web22, the lower surface of the web being opposite the web face24. The backing sheet30has a same length along length dimension L as the web22, with backing sheet first length edge32and backing sheet rear length edge34, both of which are parallel to the length dimension L. The backing sheet first length edge32is essentially aligned with the web first length edge26, but the backing sheet rear length edge34underlies an intermediate portion of the web22, thereby giving the backing sheet30a width W′ which is less than W, e.g., W′<W, as shown inFIG. 2. Thus, backing sheet40has essentially a same length dimension L as the web22but with a smaller width dimension W′ than the web22. The backing sheet has a backing sheet top surface36and a backing sheet rear surface38.

The first length edge26of the shingle comprises at least one and preferably plural cut-outs40. The non-limiting example ofFIG. 1shows four full and one partial cut-out40(the partial cut-out being the left-most cut-out40inFIG. 1). The cut-outs40may have a rectangular or (more preferably) a quasi-trapezodial shape. Different numbers and different shapes of cut-outs40may be provided in other examples. Backing segments42of a top surface of backing sheet30, having shapes corresponding to the cut-outs40, are exposed through the cut-outs40. Between adjacent cut-outs40a shingle tab50is provided on web22.FIG. 1shows five shingle tabs50, but it should be understood that the number of cut-outs40and shingle tabs50can vary in different embodiments. Preferably the exposed backing segments42have a texture, color, or pattern or type of granule application that is different or visibly contrasting with a portion of web22that will be exposed upon installation, the exposed portion including shingle tabs50(seeFIG. 4).

The roofing shingle20ofFIG. 1-FIG. 8comprises a first series of sealant material sites60and a second series of sealant material sites62provided on the shingle20.FIG. 1-FIG. 7show the material sites60as being provided on face24of shingle20;FIG. 8shows the material sites as being provided on a rear surface of shingle20(8), e.g., on backing sheet rear surface38.

For the embodiment ofFIG. 1-FIG. 7,FIG. 4shows an enlarged portion of roofing shingle20and various relationships between the material sealant sites of the same series and the material sealant sites of different series. The sealant material sites60of the first series are provided along a first sealant axis66which is essentially parallel to the length dimension L of the web22. The sealant material sites60of the first series are discontinuous along the first sealant axis66and are discrete and separated from one another along the first axis66by a first interval70.

The sealant material sites62of the second series are provided along a second sealant axis68which is essentially parallel to the length dimension L of the web22. With respect to the width dimension W of the shingle, the second series of sealant material sites62is farther than the first series of sealant material sites60to the first length edge26of the shingle, e.g., the second sealant axis68is farther from first length edge26than first sealant axis66. As such, the first sealant axis66and second sealant axis68are spaced apart by a distance D with respect to the width dimension W. Moreover, as shown in each ofFIG. 1-FIG. 9, the first axis66of the sealant material sites60of the first series and the second axis68of the sealant material sites62of the second series are spaced away from the tabs50in the width dimension W. Both the first sealant axis66and the second sealant axis68extend from the left width edge28to the right width edge29of web22.

Both the sealant material sites60of the first series and sealant material sites62of the second series may comprise deposits of adhesive material, such as an asphalt that has been modified with a thermoplastic such-as; SBS Styrene-Butadiene, Rubber, Latex modifier, polyethylene, GTR (ground Tire Rubber) and polypropylene, for example. Non-asphalt sealant materials may also be utilized as the sealant material sites60. The adhesive property of the sealant material sites60of the first series and sealant material sites62of the second series facilitate adherence to an overlaid shingle, e.g., to a shingle which overlays the roofing shingle20which bears the sealant material sites. As shown inFIG. 4, the sealant material sites60of the first series and sealant material sites62of the second series each have essentially the same shape or configuration, such as a rounded rectangle, e.g., a rectangle with rounded or beveled corners. Other shapes and configurations are also possible. In the example embodiment and mode shown inFIG. 4, each sealant material site has sealant material site length74in the length dimension L, and a sealant material site width of76in the width dimension W. Each of first sealant axis66and second sealant axis68extend substantially through a center of the width of the sealant material sites that are aligned along the respective axes.

In an example embodiment and mode shown inFIG. 4, with respect to the length dimension L, a first site621of the second series of sealant material sites62is substantially aligned between neighboring first and second sites601,602, respectively of the first series of sealant material sites60, and a second site622of the second series of sealant material sites62which neighbors the first site621of the second series of sealant material sites62is substantially aligned between neighboring third and fourth sites603,604, respectively, of the first series of sealant material sites60. This pattern may continue over the length of the shingle.

The second interval72which separates the sealant material sites62of the second series along the second axis68is thus different than the first interval70which separates the sealant material sites60of the first series along the first sealant axis66. In an example embodiment and mode ofFIG. 4, the second interval72is greater than the first interval70. This means that the first series of sealant material sites has more sealant material sites, and thus more sealant/adhesive material, than the second series of sealant material sites.

The difference between the second interval72and first interval70offers several advantages. A first advantage is that a lower edge of the roofing shingle20is provided with greater adhesion potential, e.g., greater attractive force to an overlying shingle. Provision of greater sealant/adhesion is beneficial since environmental forces such as wind tend to pry beneath the overlying shingle from the lower edge of the underlying roofing shingle20, e.g., from the direction of the eaves or lower portion of the roof, e.g., in the direction E shown inFIG. 4.

A second advantage in having interval72be greater than interval70is that a fewer number of sealant material sites62of the second series saves cost of production in requiring less sealant/adhesive material.

A third advantage in having interval72be greater than interval70is that the greater second interval72for the sealant material sites62of the second series better promotes water drainage and dissipation, should water or moisture leak between the roofing shingle20and an overlaid shingle. As shown inFIG. 4, any water or moisture on the roof is more likely to ingress between shingles from the apex of the roof. Accordingly, water or moisture may drain in various downward directions, such as the directions of arrows M as shown inFIG. 4. With a greater second interval72, and fewer sealant material sites62of the second series, there is less sealant blockage to water from above along the sealant material sites62of the second series, and thus better downward drainage opportunities. Minimizing moisture between shingles is very important, even on roofs in which galvanized nails may be used to install the shingles.

As mentioned before, backing sheet first length edge32is substantially aligned with the first length edge26of the shingle. That is, the backing sheet first length edge32is directly beneath the first length edge26of the shingle tabs50of web22. However, since the backing sheet30has smaller width than web22, the backing sheet rear length edge34underlies the web22, and is preferably substantially aligned under the web22with at least a lower edge78of the sealant material sites62of the second series (seeFIG. 4). As such, the edge78of the sealant material sites62essentially overlies backing sheet rear length edge34. In some drawings, therefore, only one of backing sheet rear length edge34or edge78of the sealant material sites62may be shown for sake of simplicity.

Whereas the example embodiment and mode ofFIG. 1-FIG. 7shows the material sites60as being provided on face24of the web22;FIG. 8shows the material sites as being provided on a rear surface of shingle20(8), such as backing sheet rear surface38. All foregoing descriptions of the sealant sites60of example embodiment and mode ofFIG. 1-FIG. 7, including but not limited to the nature, configuration, intervals, composition, advantages, etc., are applicable also for the sealant sites60(8) and62(8) of embodiment and mode ofFIG. 8, except that the sealant cites60(8) and62(8) are provided along first sealant axis66(8) and second sealant axis68(8) that are on the backing sheet rear surface38rather than on web face24. In the example embodiment and mode ofFIG. 8, first sealant axis66is slightly spaced away from and parallel to the backing sheet first length edge32on the backing sheet rear surface38, and second sealant axis68is slightly more spaced away from and parallel to the backing sheet first length edge32on the backing sheet rear surface38.

The description of the sealant material sites60of the first series and the sealant material sites62of the second series, and the first interval70and the second interval72, has been described above in the context of a laminated roofing shingle20comprising two layers, e.g., web22and backing sheet30. It should be understood, however, that the configuration and arrangement of the sealant material sites60of the first series and sealant material sites62of the second series and their respective infra-series intervals70,72may be applied to single layer shingles, and at least some of the comparable advantages may also be obtained in single layer shingles. For example, in an embodiment and mode corresponding toFIG. 1-FIG. 4, the sealant material sites60may be provided on face24of a single layer shingle, or in an embodiment and mode corresponding toFIG. 8, the sealant material sites60may be provided on a rear surface of a single layer shingle.

Another advantage of the roofing shingle20herein described is an enhanced nailing zone80. In an example embodiment and mode, the one or more cut-outs40of web22comprise a cut-out upper length edge82that is parallel to the length dimension L of the shingle. The cut-out upper length edges82of the plural cut-outs40are aligned along cut-out axis84along the length dimension L of the roofing shingle20. The nailing zone80extends between the edge78of the sealant material sites62and the cut-out axis84, and is defined by the left width edge28, right width edge29, edge78of the sealant material sites62, and cut-out axis84, as shown inFIG. 2-FIGS. 5 and 7.FIG. 4differs fromFIG. 5by showing the nailing zone80with hatching. Advantageously, applying a nail in the nailing zone80causes the nail to penetrate both the web22and the backing sheet30of the roofing shingle20, as well as the top lap or upper portion of an underlying roofing shingle.

FIG. 6shows that plural nails86may be utilized in the nailing zone80to apply roofing shingle20to a roof, e.g., through underlayment membrane into a roof deck. For an example shingle of length dimension L=42 and width W=14, in accordance with some local building code regulations four nails86may be utilized. In such example embodiment, a nailing zone distance Z (see, e.g.,FIG. 2) of the nailing zone80in the width dimension W from the cut-out axis84to the edge78of the sealant material sites62is substantially 1.5 inches. In an example implementation, with respect to the width dimension of the shingle the nailing zone is distanced substantially six inches from the first length edge of the shingle. The nailing zone80as bounded by the cut-out axis84and the edge78of the sealant material sites62is clearly visible so that the installer may easily determine where to apply the nails86. Moreover, the substantial size of the nailing zone80provides the installer with considerable latitude as to where to install the nails86along the width dimension W of the roofing shingle20. In addition, the size of the nailing zone enables the installer to apply the nails86at any point within the nailing zone80, and without regard to slope of the roof. In prior art roofing installation the slope of the roof was a limiting factor for placement of the nails, e.g., in order to assure that the nail penetrated not only the roofing shingle20but also an underlying shingle. The substantial nailing zone80of the technology disclosed herein provides greater assurance that the nails86penetrate and secure the roofing shingle20and underlying shingles regardless of roof slope.

The fact that the there are fewer sealant material sites62of the second series than sealant material sites60of the first series provides an additional advantage of less possibility for the installer to accidentally insert a nail86through a sealant material site, thereby essentially substantially reducing the opportunity for the installer to gum up a nail gun by driving a nail through sealant material/adhesive.

Each sealant material site60essentially serves as an anchor point for an adjacent shingle, whether an overlaying adjacent shingle in the case of the example embodiment and mode ofFIG. 1-FIG. 7, or an underlying adjacent shingle in the case of the example embodiment and mode ofFIG. 8. In one of its example aspects various embodiments and modes of roofing shingles described herein have a predetermined number of discontinuous sealant material sites60chosen, located, and/or formed to avoid interference with fasteners such as nails86. In an example implementation, the predetermined number of discontinuous sealant material sites60is chosen to exceed a ratio relative to a number of nails per shingle required by local building regulations. The predetermined number of discontinuous sealant material sites60of the shingles described herein is in a ratio of at least 3:1 to the number of nails per shingle required by local building regulations. For example, in a high-wind or storm/hurricane area, local building regulations may require six nails per shingle. Accordingly, in an example embodiment and mode, the predetermined number of discontinuous sealant material sites60is eighteen or more. More preferably, for a shingle having length L=42, the ratio may exceed 5:1, with a preferred number of discontinuous sealant material sites60being thirty-two.

FIG. 9shows another example embodiment and mode of shingle20(9) that includes sealant material sites60, but only the first series of sealant material sites60. The example embodiment and mode ofFIG. 9differs from the example embodiment and mode ofFIG. 1-FIG. 7, or the example embodiment and mode ofFIG. 8, only by omission of the second series62of sealant material sites. In all other respects the shingle20(9) ofFIG. 9is essentially identical to the shingle20of the embodiment and mode ofFIG. 1-FIG. 7or the shingle20(8) ofFIG. 8. The example embodiment and mode ofFIG. 9shows a shingle having at least eighteen discontinuous sealant material sites60. For a shingle having length L of substantially 42, at least eighteen and preferably substantially 32 sealant material sites60are provided. The number of discrete sealant material sites60thus afford sufficient sealing with an adjacent shingle, but are numbered in a manner to avoid likelihood of being nailed through so as to avoid interfering with the nailing attachment.

In another of its aspects the technology disclosed herein concerns methods of installing roofing shingles on a roof. The methods described herein may be applicable to any of the example embodiment and modes of shingles herein described, such as, for example, shingle20, shingle20(8), and shingle20(9). Each of the shingles comprises a web configured with a length dimension of L=C*I units of measure, L and I being even integers of a measurement unit and C being an odd integer of the measurement unit.FIG. 11shows example acts or steps involved in a generic mode of a roofing method. The generic mode ofFIG. 11and other modes such asFIG. 12described herein refer to courses of installation and offsets or increments. In general, a “course” of shingles can be conceptualized as a row of shingles extending in a length direction of the roof, with each course of row progressing from, e.g., at least partially overlapping, a previous course in a direction from the eaves to the peak of the roof.

Act 11-1 comprises, for a first course of installation, applying an entire shingle to the underlayment of the roof. It should be understood that, if the method begins near the eaves of the roof, a starter shingle may have first been applied in customary manner. As using herein, “applying” or “application” may refer to any technique of affixing or securing the roofing shingle20to the roof, such as by using a fastener, such as nails86or staples, for example.

Act 11-2 comprises, for each of X=2, . . . J courses of installation, J being an integer, two sub-acts, e.g, sub-act 11-2(a) and sub-act 11-2(b). Sub-act 11-2(a) comprises forming from an Xthshingle, an Xthshingle major portion having a length L−((X−1)*I) and a Xthshingle minor portion having a length L−L−((X−1)*I. Sub-act 11-2(b) comprises applying the Xth shingle major portion over at least a portion of an (X−1)thshingle major portion, e.g., a shingle major portion of the underlying shingle of the previous course, and to the underlayment.

Act 11-3 comprises, for each of Y=J+1, . . . C courses of installation, applying one of the Xthshingle minor portions over at least a portion of course Y−1 and to the underlayment. In the method ofFIG. 11, edges of the shingle major portions and shingle minor portions applied for courses 2−C are preferably substantially aligned in the length dimension with an edge of the entire shingle applied for the first course.

In generic embodiment and mode may further comprise applying the shingle major portions and the shingle minor portions of the respective courses by affixing or nailing the shingle major portions and the shingle minor portions in a nailing zone of the respective shingle major portions and the shingle minor portions.

In the generic and other example embodiment and modes, the method further comprises, after performing acts (1)-(3), applying one or more entire shingles to each of the C courses to abut or overlap a shingle, a shingle major portion, or a shingle minor portion already in the respective course, to fill out the longitudinal dimension of the roof along the respective course. The method may further optionally comprise installing further courses up the roof toward the peak according to acts (1)-(3).

FIG. 12shows how the generic method ofFIG. 11can be implemented using a particular roofing shingle, such as shingle20, shingle20(8), or shingle20(9), for example. In theFIG. 12example, a ratio of the length dimension L of the shingle to the width dimension W of the shingle is 3:1. The web22of each shingle is configured with a width W in a width dimension, and wherein W=L/3. In an example implementation, a length of the shingle along the length dimension is 42 inches and a width of the shingle along the width dimension is 14 inches. In the example implementation ofFIG. 12, the length of the second interval72is three inches and the length of the first interval70is one inch. As such, a ratio of the second interval72to the first interval70may be 3:1. In the example embodiment and mode ofFIG. 12, the sealant material sites of the first series and the second series have a length74in the length dimension of substantially 1 inch and a width76in the width dimension of substantially ⅜ inch. The nailing zone distance Z is substantially 1.5 inches.

Thus, in the example embodiment and mode ofFIG. 12, L=42, C=7, and I=6. The method ofFIG. 12further comprises the following acts 9-(i) through 9-(vii):

9-(i): for the first course of installation, applying an entire first shingle20-9-1to the underlayment of the roof.

9-(ii) for the second course of installation, removing a 6 inch length of a second shingle20-9-2and applying a remaining 36 inch portion of the second shingle over a portion of the first shingle20-9-1and to the underlayment whereby along the length dimension an edge of the first shingle20-9-1is substantially aligned with an edge of the remaining 36 inch portion of the second shingle20-9-2.

9-(iii) for the third course of installation, removing a 12 inch length of a third shingle20-9-3and applying a remaining 30 inch portion of the third shingle20-9-3over a portion of the 36 inch portion of the second shingle20-9-2and to the underlayment whereby along the length dimension an edge of the 36 inch portion of the second shingle20-9-2is substantially aligned with an edge of the remaining 30 inch portion of the third shingle20-9-3.

9-(iv) for the fourth course of installation, removing an 18 inch length of a fourth shingle20-9-4and applying a remaining 24 inch portion of the fourth shingle20-9-4over a portion of the 30 inch portion of the third shingle20-9-3and to the underlayment whereby along the length dimension an edge of the 30 inch portion of the third shingle20-9-3is substantially aligned with an edge of the remaining 24 inch portion of the fourth shingle20-9-4.

9-(v) for the fifth course of installation, applying a removed 18 inch length of shingle20-9-4′ over a portion of the 24 inch portion of the fourth shingle20-9-4and to the underlayment whereby along the length dimension an edge of the 24 inch portion of the fourth shingle20-9-4is substantially aligned with an edge of the removed 18 inch length of shingle20-9-4′.

9-(vi) for the sixth course of installation, applying a removed 12 inch length of shingle20-9-3′ over the removed 18 inch length of shingle20-9-4′ and to the underlayment whereby along the length dimension an edge of the removed 18 inch length of shingle20-9-4′ is substantially aligned with an edge of the removed 12 inch length of shingle20-9-3′.

9-(vii) for the seventh course of installation, applying a removed 6 inch length of shingle20-9-2′ over the removed 12 inch length of shingle20-9-3′ and to the underlayment whereby along the length dimension an edge of the removed 12 inch length of shingle20-9-3′ is substantially aligned with an edge of the removed 6 inch length of shingle20-9-2′.

In an example implementation, the removed 18 inch length of shingle20-9-4′ is removed from the fourth shingle20-9-4; the removed 12 inch length of shingle20-9-3′ is removed from the third shingle20-9-3; and the removed 6 inch length of shingle20-9-2′ is removed from the second shingle20-9-2.

As mentioned above, the method of the example embodiment and mode ofFIG. 12may further comprise applying one or more entire shingles to each of the seven courses to abut a shingle, a shingle major portion, or a shingle minor portion already in the respective course, to fill out the longitudinal dimension of the roof along the respective course. The method ofFIG. 12may further optionally comprise installing further courses up the roof toward the peak according to acts (1)-(3) ofFIG. 11.

In the example embodiment and mode ofFIG. 12, 56 shingles are installed per average square with substantially no shingle waste. On average, eight fewer shingles are utilized per square. Thus, on a 40 square job/roof, the example embodiment and mode requires 6400 fewer nails, 320 fewer shingles, and 2-4 hours less in installation time.

A shingle of length L being substantially 42 and width W of substantially 14 has several advantages, as understood from the foregoing. Another example advantage is that the plural packages90of shingles may be stored in a substantially square pattern on a loading or storage pallet92, for example. For example,FIG. 10shows storing three such packages90of shingles abreast on a square pallet92. Successive layers of shingle packages90may be stacked above the base or lowest row of shingles, preferably with differing orientation of package layers. For example, the lowest or base layer may be in a north-south orientation, with the next highest layer being in an east-west orientation, and a yet succeeding (third) layer being in the north-south orientation. Any number of layers may be stacked in this manner, each layer being essentially square in footprint. The number of layers may be chosen so as to give the entire pallet load a cubic shape. Storage of packages90of shingles in an essentially perfect square facilitates even weight distribution from successively layers that may stacked on the pallet92. Even weight distribution is preferable to have imbalance or partial overhang of a packages90of shingles, particularly in view of the thermoplastic nature of the shingles, so as not to damage shingles.

As used herein, “lower” generally connotes a lower direction, e.g., in the direction of eves of a roof, rather than apex. Conversely, “upper” or “higher” refers to an apex direction of a roof. Such terms are understood to include reference to orientation of a shingle as the shingle is intended to be installed on a roof. Further, any reference to “substantially” or “essentially” or “approximately” in terms of distance or dimension or displacement means within 0.50 inch, plus or minus. When not used in terms of length, these words mean plus or minus 5% of the property or quantity mentioned.