Pattern randomization of a laminated roofing shingle

A method of producing laminated roofing shingles is provided, wherein the shingles are of a dragon's tooth type, and shingles made in accordance with the method, and packages of such shingles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional application claims priority from U.S. provisional application Ser. No. 61/285,596 filed Dec. 11, 2009, the complete disclosure of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

In the prior art, it is known to produce laminated roofing shingles. Most particularly, it is known to produce laminated roofing shingles wherein the shingles are comprised of a fiber sheet or mat that is impregnated with a bituminous material, such as asphalt, and with granules applied on a surface of the shingles that are to be weather-exposed in the installed condition, and with generally smaller particles such as mica, sand or the like applied to the rear of the shingles, to prevent multiple shingles in a given stack or package from adhering to each other.

It is also known in the roofing art that laminated shingles may be made by cutting shingle material of the type described above, to have tabs, with spaces between the tabs, and wherein strips of additional shingle material are applied to the posterior surfaces of the shingle material having tabs thereon, to underlie the spaces between adjacent tabs. Generally such posterior-applied shingle material is of a shorter dimension than the anterior shingle layer, in that it need not extend from the lower ends of the tabs, up to the upper end of the headlap portion, although, such a full height posterior layer can be provided, if desired.

It is generally recognized that it is more economical to provide a posterior layer of shingle material that is slightly more than half the height of the anterior layer of shingle material, so that it extends from the lower ends of the tabs of the anterior layer, to just above the upper ends of the slots or cutouts, so that the slots between adjacent tabs are fully covered.

It has been recognized that highly desirable, aesthetic effects can be obtained by using an anterior layer of shingle material that has wide slots between adjacent tabs. Such an aesthetic effect is known as a “dragon's tooth” effect.

Examples of a dragon's tooth effect exist in U.S. Pat. Nos. 6,044,608; 6,355,132 and U.S. Pat. No. 7,607,275, the complete disclosures of which are herein incorporated by reference.

It has been found that, when dragon's tooth type laminated shingles are laid up on a roof, if the shingles were produced on a production line with a continuous and repeating pattern cut into the shingle material by means of a pattern of blades on the circumference of a cutting cylinder, thereafter, when the shingles thus manufactured are laid up in courses on a roof, there may appear a pattern to the thus laid-up shingles that may not be desirable, such as, the appearance of the dragon's teeth in a generally straight line, often appearing as a sloped line of teeth, when the roof with shingles thus applied is viewed from ground level.

THE PRESENT INVENTION

The present invention is directed to an apparatus and process for manufacturing laminated shingles of the type described above, wherein undesirable patterns of shingles are minimized, or at least reduced, when the shingles are laid up in courses on a roof, such that randomization of the shingles is achieved, avoiding undesirable patterns. Accordingly, the present invention is aimed at increasing the randomization of a laminated roofing shingle pattern cut design, so that when the cut design is incorporated into shingles and they are applied to a roof, such will minimize application patterning for multiple methods of application. The present invention is also directed to the shingles themselves and packages of such shingles.

SUMMARY OF THE INVENTION

The present invention provides a laminated roofing shingle cut pattern design that may or may not incorporate a mixing of production lanes of cut shingles, in the same bundle or package, such that, when shingles from a given package are installed on a roof, there will result a more random application and aesthetically pleasing appearance to the roof.

Accordingly, it is an object of this invention to provide a novel shingle cut pattern, for cutters in a shingle production line.

It is a further object of this invention to cut multiple shingles of a dragon's tooth type, on a single production line.

It is yet another object of this invention to provide novel shingles and a more random stacking of shingles that are cut from a single production line, in a given bundle or package, for application to a roof with an enhanced randomization, and less apparent patterning.

Other objects and advantages of the present invention will be readily apparent upon a reading of the following brief descriptions of the drawing figures, the detailed descriptions of the preferred embodiments and appended claims.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail, reference is first made toFIG. 1, wherein a sheet of shingle material20is illustrated, as comprising a web or mat of suitable material such as fiberglass, impregnated with a bituminous material such as asphalt, and with granules applied to one surface, that is to be the weather-exposed surface when installed on a roof, and with smaller particles such as mica, sand or the like applied on the opposite surface that is to be the surface of the shingle that is unexposed when installed on a roof. The shingle material20is delivered along a path, in the direction of the arrow21.

As the shingle material20is moved along the generally horizontal path21, it passes above or beneath a plurality of pattern cutters22,23, each of the generally cylindrical type.

The generally cylindrical pattern cutter22is mounted on a suitable rotating shaft24, rotatable in a given direction as indicated by the arrow25, and driven preferably by means of a motor26.

The cutter22will preferably have an even number of cutting teeth29on each end27,28thereof, with adjacent cutting teeth on each end27or28being spaced apart by a given center line distance30, measured between the center lines of the cutting teeth on each end27, or28of the cutter22.

The shaft24may also carry and likewise drive, disk-like cutters31,32,33,34and35, for cutting a plurality of strips B′, D′, A′ and C′, between dragon's tooth shingle layers C and B, as shown.

Thus, the cutter22when rotated, will cut shingle layers with dragon's tooth type slots between what will become anterior shingle layers A and C.

Similarly, the cutter23, carried on the shaft40for rotation therewith in the direction of the arrow41, will have cutting teeth42on its outer cylindrical surface, for cutting dragon's tooth type cuts in the shingle layer disposed thereabove or therebeneath, to generate dragon's tooth cuts in what will become anterior shingle layers B and D of a laminated shingle, as shown at the lower end ofFIG. 1. The center line spacing43between adjacent cutting teeth for the cutter23will be a different, smaller, center line spacing43than the center line spacing30described above.

The cylindrical cutter23will preferably have its cutting edges42arranged thereon, to cut an uneven number of dragon's tooth cuts by means of the cylindrical cutter23, preferably by at least 5% more cuts than will be cut by the cutter22.

Thus, the cutter23will cut in the shingle material20, a greater number of teeth45,46per lineal yard, than will the cutter22cut a given number of lineal teeth47,48per lineal yard.

Both cutters22and23cut against anvil rollers (not shown) with the shingle material20between the cutters22,23and the anvil rollers.

The shaft40can be connected to be driven along with the shaft24by means of the motor26, or, alternatively, can be driven by its own motor50, shown in phantom inFIG. 1, and can be connected to an end of the shaft24by means of a slip-fit connection, as shown in phantom at51, if desired.

Thus, the shingle cutting mechanism illustrated inFIG. 1will produce anterior, dragon's tooth type shingle material layers A and C at one side of the illustration ofFIG. 1, and similar dragon's tooth type anterior shingle material layers, but having a greater number of teeth per lineal yard, B and D at the lower end ofFIG. 1.

In between the dragon's tooth type layers B and C, there are provided partial height posterior shingle material layers B′, D′, A′ and C′ of shingle material, referred to as “shim” layers.

It will be understood that in some production lines, the dragon's tooth type layers of shingle material can be produced at other locations transversely of the production line, with (shim) layers of shorter height shingle material that are designed to be posterior layers of shingle material, disposed transversely outwardly, of the dragon's tooth type anterior layers of shingle material, or otherwise laterally disposed relative to the dragon's tooth type anterior layer of shingle material.

It is of significance that, in accordance with the present invention, the two pairs of lanes that make up the dragon's teeth layers; namely lanes A/C, and lanes B/D differ from each other. The differences can be having different numbers of teeth on the cutter22or23that cuts the dragon's tooth layers, or an even number of teeth on one of the cutters and an odd number of teeth on the other cutter. For example, one could have a much larger roller comprising one of the cutters22or23, or the rollers for the cutters22,23could both have even numbers or odd numbers, in a situation wherein both rollers have a much larger diameter. In such a case, both rollers22,23could have an even number of cutting teeth, such as one with the ability to cut8teeth and the other with the ability to cut10teeth, or alternatively one with the ability to cut9teeth and the other with the ability to cut11teeth, all of which arrangements would produce a comparable effect, such that the cutters would differ from each other so that they produce two differently cut pairs of lanes of dragon's tooth shingle material.

Similarly, the dragon's tooth type layers of shingle material B and D can be produced from a different production line than that which produces the dragon's tooth type layers A and C from the cutter22ofFIG. 1.

With reference toFIG. 2, it will be seen that the dragon's tooth layer A has laminated thereto, the backing or shim layer A′, by bringing the backing layer A′ against the posterior surface of the anterior layer A, and is adhered thereto by lamination means not shown, for delivery along a path indicated by the arrow52, to a location where a cutter53will cut the laminated shingle material ofFIG. 2to a desired length, such as, for example, 38¾ inches, from a cutter roller of approximately 42¼ inch diameter, to produce a pattern that repeats after approximately every 7 or 8 shingles. The cutters53,55,57and60, while being illustrated as blades inFIGS. 2-5, will preferably be cutting rollers of greater diameter than the length of shingle to be cut. For example, for a shingle of 38¾ inch length, the cutting rollers53,55,57,60could be 42¼ inches in diameter.

Similarly, the backing or shim layer C′ fromFIG. 1is laminated to the dragon's tooth type anterior shingle layer C as shown inFIG. 3, for likewise delivery in the direction of the arrow54, to a cutter55, for cutting the laminated shingle of a given desired length from the laminated shingle material ofFIG. 3.

InFIG. 4, a backing or shim layer B′ is brought against the posterior surface of the anterior layer B of dragon's tooth type shingle material, laminated thereagainst by means of a suitable adhesive, for delivery in the direction of the arrow56to the cutter57.

InFIG. 5, a backing or shim layer D′ is brought against the posterior surface of a dragon's tooth type layer D of shingle material, for delivery in the direction of the arrow58to a cutter60for likewise cutting the thus laminated shingle material ofFIG. 5to a desired length.

The backing layers A′, B′, C′ and D′, as shown inFIGS. 2-5have no spaced-apart tabs, but the anterior layers, A, B, C and D have a spacing between the tabs that may vary and is preferably greater than two inches and more preferably is greater than 2½ inches, such as from about 3 to 7 inches. The tabs may be of equal and/or unequal widths and each width typically is in the same range as out of the spaces therebetween. The tabs may have various shapes.

It will be noted that the cutters53,55,57and60may be disposed at different linear locations, not aligned, as viewed in the collective illustrations ofFIGS. 2-5, for enhancing the eventual randomness of shingles made in accordance with the illustrations ofFIGS. 2-5, when the shingles are packaged in a common bundle or package.

It will thus be seen, with reference toFIGS. 2-5, that laminated dragon's tooth shingles70,71,72and73are produced in accordance with the respective illustrations ofFIGS. 2-5.

With respect toFIG. 6, it will be seen that the sheet20of shingle material can pass over a roller61, then around a roller62, beneath a roller64, and back upwardly and around roller63, to continue moving horizontally.

The roller64can be raised or lowered by means of a variable tension loop provided by roller64, with the tension being supplied by a suitable spring mechanism65or the like mounted at66, which may be adjusted upwardly or downwardly as indicated by the double-headed arrow67, such that the roller64can absorb or release different lineal amounts of shingle material20toward any of the cutters53,55,57or60as may be desired, for each of the laminated layers of shingle material shown inFIGS. 2-5.

With reference now toFIG. 7, it will be seen that, in making a bundle or package of shingles, a laminated shingle70may have a laminated shingle73, with a larger number of smaller dragon's tooth slots between adjacent tabs of the anterior shingle layer disposed thereover, followed by another laminated shingle70(not shown) disposed above the shingle73, followed by another laminated shingle73(not shown) disposed over the latter shingle70, etc., such that, as a bundle or package of shingles is built up, alternating shingles70,73have their dragon's teeth facing in opposite directions, as illustrated inFIG. 7.

An alternative arrangement for bundling or packaging adjacent shingles is illustrated inFIG. 8, wherein the laminated shingle73ofFIG. 7is shown rotated in the direction of arrow74, such that its dragon's teeth are facing in the same direction as the dragon's teeth for the laminated shingle70, and disposed thereagainst, with the back surface75for the laminated shingle73being now turned to be upwardly-facing. Subsequent laminated shingles70,73may continue to be stacked in this manner, alternating as70,73,70,73etc.

InFIG. 9, the stacking of bundling arrangement is like that ofFIG. 8, except that the laminated shingle73ofFIG. 8is rotated 180° as shown by the arrow85so that its dragon teeth are oriented outwardly, as shown. It is preferred to have the dragon teeth facing in opposite directions in order to avoid building up excess thickness on one side of a bundle.

InFIG. 10, another stacking or bundling arrangement is illustrated, in which the laminated shingle73is stacked over the laminated shingle70, with its dragon's teeth facing in the same direction as are the dragon's teeth of the laminated shingle70. In this arrangement, the laminated shingle73has been rotated endwise as shown by the arrow76from the orientation of the laminated shingle73illustrated inFIG. 7, so that the right-most end of the laminated shingle73as illustrated inFIG. 7is now at the left-most end of the arrangement ofFIG. 10, and the left-most end of the laminated shingle73as shown inFIG. 7is now at the right-most end in the arrangement ofFIG. 10.

While the various arrangements ofFIGS. 7-10are presented with respect to the laminated shingles70and73, it will be understood that similar arrangements for stacking/bundling of the laminated shingles71and72may likewise be effected. Adjacent laminated shingles can be face to back as inFIG. 7, face to face as inFIGS. 8 and 9, or back to back (not shown).

Other than the various combinations of backing or shim layers relative to dragon's tooth type layers illustrated inFIGS. 2-5, it will be understood that various other arrangements may be made. For example, the backing or shim layer for the dragon's tooth layer A could be any of backing or shim layers A′, B′, C′ or D′. Likewise, any of the backing or shim layers for dragon's tooth type layer C could be any of backing or shim layers A′, B′, C′ or D′. Likewise any of the backing or shim layers for dragon's tooth layers B and D could be any of backing or shim layers A′, B′, C′ or D′. Additionally, when placing layers in a stack, any of the shingles can be turned over with their backing layer facing upwardly when going into the stack in a bundle.

It will also be apparent that other arrangements for varying the manner of stacking shingles can be effected, to further enhance the randomness of shingles in a stack, such that when a shingle installer takes shingles from a stack for application to a roof, the different orientations of the shingles in a stack, and the different orientations of shingles in multiple stacks or packages of shingles, will facilitate further avoidance of undesirable patterning as the shingles are installed on a roof.

InFIG. 11, a typical arrangement of a plurality of laminated shingles in accordance with this invention is illustrated, depending upon the desired stacking, in a suitable wrapper or package80, for shipment of the package of shingles to a site of application.

With reference toFIG. 12, a roof90is fragmentally illustrated, in which, in a lower course there are illustrated a pair of adjacent shingles70and73, with another shingle73laid up in a somewhat staggered arrangement, and principally overlying a substantial part of the shingle70, with the tab portion of the shingle73in the overlying course covering the butt or headlap portion of the shingle70in an underlying course. It will be understood that the roof90will be covered by different shingles, such as70and73, in a plurality of succeeding courses.

While the illustrations of this invention are addressed to a pair of cutting cylinders as illustrated inFIG. 1, it will be understood that in some shingle production arrangements an even larger number of cutting cylinders may be used to produce shingles that can come together or be combined separately in a bundle, or which can be produced and combined separately as an offline operation, at the same or at a later time.

In accordance with one aspect of this invention it will be understood that cylindrical cutters, when used with this invention will provide from one cutter, an even number of dragon's teeth, and with the other cutter, an uneven number of dragon's teeth when the cutting roller are of the same or similar diameter, for facilitating further randomization of dragon's teeth on the laminated shingles when they are installed on a roof.

As described above, for the cylindrical cutters, a given pattern cut may have a first center line spacing from tooth-to-tooth, and a different cutter may have a different centerline spacing, preferably with a difference in spacings of cutting teeth on cutters of 5% or greater in number.

The center line “tooth” spacings for the portions of the cutting rollers that cut the dragon's teeth could be an average spacing for the dragon's teeth cutters on any particular cutting roller. For example, usually not all of the dragon's teeth are exactly the same, with some being slightly larger and some being slightly smaller, such that the absolute center line distances from tooth to tooth would vary, whereby a given cutting roller would have an average center line spacing. A second roller for cutting other dragon's teeth could have a different average center line spacing, yet, from a given tooth to an adjacent tooth there could be some variation, but the second cutting roller would have a variation on a different scale. Thus, for two different cutting rollers, one could have a first average spacing between the means for cutting adjacent teeth, and the other roller could have a second, but different average spacing between adjacent cutting means thereon. Also, the cutting rollers could have the same number of teeth, but be of different diameters to provide different average-tooth centerline spacing.

Also, in accordance with this invention, a given pattern cut may be shorter or longer, or of different lengths and different lengths of repetition, with such different lengths being illustrated by the placement of cutters53,55,57and60as illustrated inFIGS. 2-5, for example.

By cutting dragon's teeth in accordance with this invention, as well as by stacking shingles made in accordance with this invention in varying manners, multiple differences between shingles in a stack may be produced, so as to vary large and small differences for facilitating increased randomization of dragon's tooth presentations of the shingles when the shingles are installed on a roof.

It will be apparent from the above that in accordance with this invention, a pattern cut is presented as an uneven, uniform or non-uniform pattern that results in an interlaced design having distinct patterns after separation from the original sheet20of shingle material. The pattern cut locations along a path of travel21, as illustrated inFIG. 1can be offset or staggered in relation to each other, and production lanes having distinct patterns can be combined as needed by cross-overs, and/or twisting, to combine lanes or mixing during packaging of two or more lanes, as are illustrated for example inFIGS. 7-9to increase the randomization of the cut pattern of shingles in the package, in order to improve the flexibility for multiple application methods when installing the shingles on a roof. Additionally, such may increase the randomization of the cut patterns of the shingles when applied to a roof, in order to enhance the visual aesthetics, increasing further randomization by combining one or more cut designs in the same package.

Additionally, the shingles can be stacked in a given package in accordance with any of the arrangements ofFIGS. 7-10, as well as other arrangements, in order to improve weight distribution in the package and/or to improve the balance of pattern cut layers within the package and that such mixing of production lanes as described above, to produce different packaging arrangements within a given package may further enhance the randomness and aesthetic appearance of shingles when applied to a roof.

It will be apparent from the foregoing that various modifications and alternatives to the arrangements discussed herein, as well as to the method and apparatus, may be employed, all within the spirit and scope of the invention as defined in the appended claims.