Patent ID: 12209414

DETAILED DESCRIPTION

Referring toFIGS.1and2, in some embodiments, a roofing shingle10includes a core layer12and a cap layer14. In some embodiments, the cap layer14overlays the core layer12. In some embodiments, the core layer12includes a first end16, a second end18opposite the first end16, a first edge20extending from the first end16to the second end18, and a second edge22opposite the first edge20and extending from the first end16to the second end18. In some embodiments, the cap layer14includes a first end24, a second end26opposite the first end24, a first edge28extending from the first end24to the second end26, and a second edge30opposite the first edge28and extending from the first end24to the second end26. In some embodiments, the second end18of the core layer12is offset from the second end26of the cap layer14. In some embodiments, the second end18of the core layer12is offset from the second end26of the cap layer14by a length L1.

In some embodiments, the length L1is 1 inch to 10 inches. In some embodiments, the length L1is 1 inch to 9 inches. In some embodiments, the length L1is 1 inch to 8 inches. In some embodiments, the length L1is 1 inch to 7 inches. In some embodiments, the length L1is 1 inch to 6 inches. In some embodiments, the length L1is 1 inch to 5 inches. In some embodiments, the length L1is 1 inch to 4 inches. In some embodiments, the length L1is 1 inch to 3 inches. In some embodiments, the length L1is 1 inch to 2 inches. In some embodiments, the length L1is 2 inches to 10 inches. In some embodiments, the length L1is 2 inches to 9 inches. In some embodiments, the length L1is 2 inches to 8 inches. In some embodiments, the length L1is 2 inches to 7 inches. In some embodiments, the length L1is 2 inches to 6 inches. In some embodiments, the length L1is 2 inches to 5 inches. In some embodiments, the length L1is 2 inches to 4 inches. In some embodiments, the length L1is 2 inches to 3 inches. In some embodiments, the length L1is 3 inches to 10 inches. In some embodiments, the length L1is 3 inches to 9 inches. In some embodiments, the length L1is 3 inches to 8 inches. In some embodiments, the length L1is 3 inches to 7 inches. In some embodiments, the length L1is 3 inches to 6 inches. In some embodiments, the length L1is 3 inches to 5 inches. In some embodiments, the length L1is 3 inches to 4 inches. In some embodiments, the length L1is 4 inches to 10 inches. In some embodiments, the length L1is 4 inches to 9 inches. In some embodiments, the length L1is 4 inches to 8 inches. In some embodiments, the length L1is 4 inches to 7 inches. In some embodiments, the length L1is 4 inches to 6 inches. In some embodiments, the length L1is 4 inches to 5 inches.

In some embodiments, the length L1is 5 inches to 10 inches. In some embodiments, the length L1is 5 inches to 9 inches. In some embodiments, the length L1is 5 inches to 8 inches. In some embodiments, the length L1is 5 inches to 7 inches. In some embodiments, the length L1is 5 inches to 6 inches. In some embodiments, the length L1is 6 inches to 10 inches. In some embodiments, the length L1is 6 inches to 9 inches. In some embodiments, the length L1is 6 inches to 8 inches. In some embodiments, the length L1is 6 inches to 7 inches. In some embodiments, the length L1is 7 inches to 10 inches. In some embodiments, the length L1is 7 inches to 9 inches. In some embodiments, the length L1is 7 inches to 8 inches. In some embodiments, the length L1is 8 inches to 10 inches. In some embodiments, the length L1is 8 inches to 9 inches. In some embodiments, the length L1is 9 inches to 10 inches.

In some embodiments, the length L1is 1 inch. In some embodiments, the length L1is 2 inches. In some embodiments, the length L1is 3 inches. In some embodiments, the length L1is 4 inches. In some embodiments, the length L1is 5 inches. In some embodiments, the length L1is 6 inches. In some embodiments, the length L1is 7 inches. In some embodiments, the length L1is 8 inches. In some embodiments, the length L1is 9 inches. In some embodiments, the length L1is 10 inches.

In some embodiments, the offset of the core layer12from the cap layer14forms a side lap32. In some embodiments, the first end16of the core layer12is offset from the first end24of the cap layer14. In some embodiments, the first end16of the core layer12is offset from the first end24of the cap layer14by a length L2.

In some embodiments, the length L2is 1 inch to 10 inches. In some embodiments, the length L2is 1 inch to 9 inches. In some embodiments, the length L2is 1 inch to 8 inches. In some embodiments, the length L2is 1 inch to 7 inches. In some embodiments, the length L2is 1 inch to 6 inches. In some embodiments, the length L2is 1 inch to 5 inches. In some embodiments, the length L2is 1 inch to 4 inches. In some embodiments, the length L2is 1 inch to 3 inches. In some embodiments, the length L2is 1 inch to 2 inches. In some embodiments, the length L2is 2 inches to 10 inches. In some embodiments, the length L2is 2 inches to 9 inches. In some embodiments, the length L2is 2 inches to 8 inches. In some embodiments, the length L2is 2 inches to 7 inches. In some embodiments, the length L2is 2 inches to 6 inches. In some embodiments, the length L2is 2 inches to 5 inches. In some embodiments, the length L2is 2 inches to 4 inches. In some embodiments, the length L2is 2 inches to 3 inches. In some embodiments, the length L2is 3 inches to 10 inches. In some embodiments, the length L2is 3 inches to 9 inches. In some embodiments, the length L2is 3 inches to 8 inches. In some embodiments, the length L2is 3 inches to 7 inches. In some embodiments, the length L2is 3 inches to 6 inches. In some embodiments, the length L2is 3 inches to 5 inches. In some embodiments, the length L2is 3 inches to 4 inches. In some embodiments, the length L2is 4 inches to 10 inches. In some embodiments, the length L2is 4 inches to 9 inches. In some embodiments, the length L2is 4 inches to 8 inches. In some embodiments, the length L2is 4 inches to 7 inches. In some embodiments, the length L2is 4 inches to 6 inches. In some embodiments, the length L2is 4 inches to 5 inches.

In some embodiments, the length L2is 5 inches to 10 inches. In some embodiments, the length L2is 5 inches to 9 inches. In some embodiments, the length L2is 5 inches to 8 inches. In some embodiments, the length L2is 5 inches to 7 inches. In some embodiments, the length L2is 5 inches to 6 inches. In some embodiments, the length L2is 6 inches to 10 inches. In some embodiments, the length L2is 6 inches to 9 inches. In some embodiments, the length L2is 6 inches to 8 inches. In some embodiments, the length L2is 6 inches to 7 inches. In some embodiments, the length L2is 7 inches to 10 inches. In some embodiments, the length L2is 7 inches to 9 inches. In some embodiments, the length L2is 7 inches to 8 inches. In some embodiments, the length L2is 8 inches to 10 inches. In some embodiments, the length L2is 8 inches to 9 inches. In some embodiments, the length L2is 9 inches to 10 inches.

In some embodiments, the length L2is 1 inch. In some embodiments, the length L2is 2 inches. In some embodiments, the length L2is 3 inches. In some embodiments, the length L2is 4 inches. In some embodiments, the length L2is 5 inches. In some embodiments, the length L2is 6 inches. In some embodiments, the length L2is 7 inches. In some embodiments, the length L2is 8 inches. In some embodiments, the length L2is 9 inches. In some embodiments, the length L2is 10 inches.

In some embodiments, the length L1is equal to the length L2. In some embodiments, the length L1is different from the length L2. In some embodiments, the offset of the core layer12from the cap layer14forms an extended portion35.

In some embodiments, the core layer12has a length L3. In some embodiments, the length L3is 30 inches to 60 inches. In some embodiments, the length L3is 30 inches to 50 inches. In some embodiments, the length L3is 30 inches to 40 inches. In some embodiments, the length L3is 40 inches to 60 inches. In some embodiments, the length L3is 40 inches to 50 inches. In some embodiments, the length L3is 50 inches to 60 inches. In some embodiments, the length L3is 30 inches. In some embodiments, the length L3is 40 inches. In some embodiments, the length L3is 50 inches. In some embodiments, the length L3is 60 inches.

In some embodiments, the cap layer14has a length L4. In some embodiments, the length L4is 30 inches to 60 inches. In some embodiments, the length L4is 30 inches to 50 inches. In some embodiments, the length L4is 30 inches to 40 inches. In some embodiments, the length L4is 40 inches to 60 inches. In some embodiments, the length L4is 40 inches to 50 inches. In some embodiments, the length L4is 50 inches to 60 inches. In some embodiments, the length L4is 30 inches. In some embodiments, the length L4is 40 inches. In some embodiments, the length L4is 50 inches. In some embodiments, the length L4is 60 inches. In some embodiments, the roofing shingle10has a total length L5. In some embodiments, the length L5is 32 inches to 66 inches.

In some embodiments, the roofing shingle10includes a head lap portion34extending from the first end24to the second end26of the cap layer14, and from the first edge28to a location36between the first edge28to second edge30of the cap layer14. In some embodiments, the roofing shingle10includes a reveal portion38extending from the first end24to the second end26of the cap layer14, and from the second edge30to the location36.

In some embodiments, the head lap portion34has a width W1. In some embodiments, the width W1is 1 inch to 16 inches. In some embodiments, the width W1is 1 inch to 15 inches. In some embodiments, the width W1is 1 inch to 10 inches. In some embodiments, the width W1is 1 inch to 5 inches. In some embodiments, the width W1is 5 inches to 16 inches. In some embodiments, the width W1is 5 inches to 15 inches. In some embodiments, the width W1is 5 inches to 10 inches. In some embodiments, the width W1is 10 inches to 16 inches. In some embodiments, the width W1is 10 inches to 15 inches. In some embodiments, the width W1is 15 inches to 16 inches. In some embodiments, the width W1is 1 inch. In some embodiments, the width W1is 5 inches. In some embodiments, the width W1is 10 inches. In some embodiments, the width W1is 15 inches. In some embodiments, the width W1is 16 inches.

In some embodiments, the reveal portion38has a width W2. In some embodiments, the width W2is 5 inches to 12 inches. In some embodiments, the width W2is 5 inches to 10 inches. In some embodiments, the width W2is 10 inches to 12 inches. In some embodiments, the width W2is 5 inches. In some embodiments, the width W2is 10 inches. In some embodiments, the width W2is 12 inches.

In some embodiments, the core layer12is composed of a polymeric material. In some embodiments, the core layer12is composed of a thermoplastic polymer. In some embodiments, the core layer12is composed of polyethylene terephthalate (“PET”). In another embodiment, the core layer12is composed of ethylene tetrafluoroethylene (“ETFE”). In some embodiments, the core layer12is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the core layer12is composed of thermoplastic polyolefin (TPO). In some embodiments, the core layer12is composed of a single ply TPO roofing membrane. In other embodiments, non-limiting examples of TPO membranes are disclosed in U.S. Pat. No. 9,359,014 to Yang et al., which is incorporated by reference herein in its entirety. In another embodiment, the core layer12includes polyvinyl chloride. In some embodiments, the core layer12is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the core layer12is composed of a natural rubber. In some embodiments, the core layer12is composed of high density polyethylene (HDPE). In some embodiments, the core layer12is composed of polypropylene (PP). In some embodiments, the core layer12is composed of a polyolefin elastomer (POE). In some embodiments, the core layer12is composed of polyvinyl chloride (PVC). In some embodiments, the core layer12includes a flame retardant additive. In some embodiments, the flame retardant additive may be clays, nanoclays, silicas, carbon black, metal hydroxides such as aluminum hydroxide, metal foils, graphite, and combinations thereof.

In some embodiments, the core layer12includes a composite material. In some embodiments, the core layer12is composed of a composite material that incorporates fiberglass into a polymer matrix of a PP, asphalt or TPO. In some embodiments, the composite materials may have a solar reflectance that is at least 20% greater than conventional composite materials. In some embodiments, the composite materials may be used as a roof attachment and a water shedding layer. In some embodiments, the composite materials, when used as roofing materials for photovoltaic modules, may increase power for such photovoltaic modules by 1% to 2%. In some embodiments, the composite materials may have a relative temperature index (RTI) of greater than 90° C. In some embodiments, the composite material may be a black thermoplastic polyolefin membrane.

As used herein, the term “building material” may include, without limitation, at least one of a roofing material, a siding, a flooring, or any combination thereof. As used herein, the term “roofing material” may include any material of a roof and may include, for example and without limitation, at least one of shingles (e.g., such as photovoltaic modules), roofing membranes (e.g., such as waterproofing membranes), underlayments, tiles, any component thereof, or any combination thereof In some embodiments, the roofing material may comprise, consist of, or consist essentially of a component of a photovoltaic module. For example, in some embodiments, the roofing material may comprise, consist of, or consist essentially of a backsheet or a portion of a backsheet (e.g., a bottom flap, a head lap, etc.). Further examples of roofing materials include, without limitation, at least one of rolled roofing, flexible rolled roofing, or any combination thereof.

In some embodiments, the composite material is a roofing composite material. In some embodiments, the roofing composite material may comprise, consist of, or consist essentially of one or more layers. For example, in some embodiments, the roofing composite material may comprise, consist of, or consist essentially of at least one of a substrate, a cap, a core, or any combination thereof In some embodiments, the substrate may have a first surface and a second surface opposite the first surface. In some embodiments, the cap may be on the first surface of the substrate. In some embodiments, the cap may be in contact with the first surface of the substrate. In some embodiments, the core may be on the second surface of the substrate. In some embodiments, the core may be in contact with the second surface of the substrate. In some embodiments, one or more layers may be located between the cap and the substrate. In some embodiments, one or more layers may be located between the core and the substrate.

In some embodiments, the core layer12has a thickness of 0.1 mm to 5 mm. In some embodiments, the core layer12has a thickness of 0.1 mm to 4 mm. In some embodiments, the core layer12has a thickness of 0.1 mm to 3 mm. In some embodiments, the core layer12has a thickness of 0.1 mm to 2 mm. In some embodiments, the core layer12has a thickness of 0.1 mm to 1 mm. In some embodiments, the core layer12has a thickness of 1 mm to 5 mm. In some embodiments, the core layer12has a thickness of 1 mm to 4 mm. In some embodiments, the core layer12has a thickness of 1 mm to 3 mm. In some embodiments, the core layer12has a thickness of 1 mm to 2 mm. In some embodiments, the core layer12has a thickness of 2 mm to 5 mm. In some embodiments, the core layer12has a thickness of 2 mm to 4 mm. In some embodiments, the core layer12has a thickness of 2 mm to 3 mm. In some embodiments, the core layer12has a thickness of 3 mm to 5 mm. In some embodiments, the core layer12has a thickness of 3 mm to 4 mm. In some embodiments, the core layer12has a thickness of 4 mm to 5 mm. In some embodiments, the core layer12has a thickness of 0.1 mm. In some embodiments, the core layer12has a thickness of 1 mm. In some embodiments, the core layer12has a thickness of 2 mm. In some embodiments, the core layer12has a thickness of 3 mm. In some embodiments, the core layer12has a thickness of 4 mm. In some embodiments, the core layer12has a thickness of 5 mm.

In some embodiments, the cap layer14includes a polymeric material. In some embodiments, the cap layer14includes polyethylene terephthalate (“PET”). In another embodiment, the cap layer14includes ethylene tetrafluoroethylene (“ETFE”). In some embodiments, the cap layer14includes an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the cap layer14includes thermoplastic polyolefin (TPO). In some embodiments, the cap layer14includes a single ply TPO roofing membrane. In other embodiments, non-limiting examples of TPO membranes are disclosed in U.S. Pat. No. 9,359,014 to Yang et al., which is incorporated by reference herein in its entirety. In another embodiment, the cap layer14includes polyvinyl chloride. In some embodiments, the cap layer14includes ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the cap layer14is composed of a natural rubber. In some embodiments, the cap layer14is composed of high density polyethylene (HDPE). In some embodiments, the cap layer14is composed of polypropylene (PP). In some embodiments, the cap layer14is composed of a polyolefin elastomer (POE). In some embodiments, the cap layer14is composed of polyvinyl chloride (PVC). In some embodiments, the cap layer14includes a flame retardant additive. In some embodiments, the flame retardant additive may be clays, nanoclays, silicas, carbon black, metal hydroxides such as aluminum hydroxide, metal foils, graphite, and combinations thereof. In some embodiments, the cap layer14includes a composite material. In some embodiments, the cap layer14is composed of a composite material that incorporates fiberglass into a polymer matrix of a PP, asphalt or TPO. In some embodiments, the cap layer14is composed of a composite material as described above with respect to the core layer12.

In some embodiments, the core layer12includes magnesium oxide (MgO). In some embodiments, the core layer12includes 35% to 50% by weight of MgO. In some embodiments, the core layer12includes 35% to 45% by weight of MgO. In some embodiments, the core layer12includes 35% to 40% by weight of MgO. In some embodiments, the core layer12includes 40% to 50% by weight of MgO. In some embodiments, the core layer12includes 40% to 45% by weight of MgO. In some embodiments, the core layer12includes 45% to 50% by weight of MgO. In some embodiments, the core layer12includes 35% by weight of MgO. In some embodiments, the core layer12includes 40% by weight of MgO. In some embodiments, the core layer12includes 45% by weight of MgO. In some embodiments, the core layer12includes 50% by weight of MgO.

In some embodiments, the core layer12includes ketone ethylene ester (KEE). In some embodiments, the core layer12includes a PVC-KEE hybrid membrane. In some embodiments, the roofing shingle10is adapted to be a component of a photovoltaic system that includes a fire resistance that conforms to standards under UL 790/ASTM E 108 test standards. In some embodiments, the roofing shingle10includes a Class A rating when tested in accordance with UL 790/ASTM E 108.

In some embodiments, the core layer12and the cap layer14are welded to one another. In some embodiments, the core layer12and the cap layer14are ultrasonically welded to one another. In some embodiments, the core layer12and the cap layer14are heat welded to one another. In some embodiments, the core layer12and the cap layer14are thermally bonded to one another.

In some embodiments, the core layer12and the cap layer14are adhered to one another by an adhesive layer15(seeFIG.2A). In some embodiments, the adhesive layer15includes an adhesive. In some embodiments, the adhesive layer15may include butyl, polyvinyl butyrate, acrylic, silicone, or polycarbonate. In some embodiments, the first adhesive layer15may include pressure sensitive adhesives.

In some embodiments, the core layer12and the cap layer14are laminated. In some embodiments, the core layer12and the cap layer14are co-extruded. In some embodiments, the core layer12and the cap layer14are mechanically attached to one another. In some embodiments, the core layer12and the cap layer14are attached to one another by at least one fastener. In some embodiments, the core layer12and the cap layer14are attached to one another by a plurality of fasteners. In some embodiments, the core layer12and the cap layer14are attached to one another by deforming one of the core layer12and the cap layer14into the other one of the core layer12and the cap layer14. In some embodiments, the core layer12and the cap layer14are attached to one another by deforming a portion of one of the core layer12and the cap layer14into the other one of the core layer12and the cap layer14. In some embodiments, the core layer12and the cap layer14are attached to one another by forming at least one hole in one or both of the core layer12and the cap layer14and dispensing molten material into the at least one hole to connect the core layer12and the cap layer14. In some embodiments, non-limiting examples of fasteners, fastening means and methods for fastening, connecting and attaching the core layer12to the cap layer14are disclosed in U.S. Pat. No. 7,833,371 to Binkley et al, U.S. Pat. No. 8,006,457 to Binkley et al, U.S. Pat. No. 8,127,514 to Binkley et al, and U.S. Pat. No. 8,316,608 to Binkley et al, each of which is incorporated by reference herein in its entirety.

In some embodiments, the cap layer14has a thickness of 0.1 mm to 5 mm. In some embodiments, the cap layer14has a thickness of 0.1 mm to 4 mm. In some embodiments, the cap layer14has a thickness of 0.1 mm to 3 mm. In some embodiments, the cap layer14has a thickness of 0.1 mm to 2 mm. In some embodiments, the cap layer14has a thickness of 0.1 mm to 1 mm. In some embodiments, the cap layer14has a thickness of 1 mm to 5 mm. In some embodiments, the cap layer14has a thickness of 1 mm to 4 mm. In some embodiments, the cap layer14has a thickness of 1 mm to 3 mm. In some embodiments, the cap layer14has a thickness of 1 mm to 2 mm. In some embodiments, the cap layer14has a thickness of 2 mm to 5 mm. In some embodiments, the cap layer14has a thickness of 2 mm to 4 mm. In some embodiments, the cap layer14has a thickness of 2 mm to 3 mm. In some embodiments, the cap layer14has a thickness of 3 mm to 5 mm. In some embodiments, the cap layer14has a thickness of 3 mm to 4 mm. In some embodiments, the cap layer14has a thickness of 4 mm to 5 mm. In some embodiments, the cap layer14has a thickness of 0.1 mm. In some embodiments, the cap layer14has a thickness of 1 mm. In some embodiments, the cap layer14has a thickness of 2 mm. In some embodiments, the cap layer14has a thickness of 3 mm. In some embodiments, the cap layer14has a thickness of 4 mm. In some embodiments, the cap layer14has a thickness of 5 mm.

In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 5 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 4 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 3 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 2 mm. In some embodiments, the roofing shingle10has a thickness of 0.2 mm to 1 mm.

In some embodiments, the roofing shingle10has a thickness of 1 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 5 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 4 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 3 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm to 2 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 5 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 4 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm to 3 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 5 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm to 4 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm to 5 mm.

In some embodiments, the roofing shingle10has a thickness of 5 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 5 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 5 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 5 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 5 mm to 6 mm. In some embodiments, the roofing shingle10has a thickness of 6 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 6 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 6 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 6 mm to 7 mm. In some embodiments, the roofing shingle10has a thickness of 7 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 7 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 7 mm to 8 mm. In some embodiments, the roofing shingle10has a thickness of 8 mm to 10 mm. In some embodiments, the roofing shingle10has a thickness of 8 mm to 9 mm. In some embodiments, the roofing shingle10has a thickness of 9 mm to 10 mm.

In some embodiments, the roofing shingle10has a thickness of 0.2 mm. In some embodiments, the roofing shingle10has a thickness of 1 mm. In some embodiments, the roofing shingle10has a thickness of 2 mm. In some embodiments, the roofing shingle10has a thickness of 3 mm. In some embodiments, the roofing shingle10has a thickness of 4 mm. In some embodiments, the roofing shingle10has a thickness of 5 mm. In some embodiments, the roofing shingle10has a thickness of 6 mm. In some embodiments, the roofing shingle10has a thickness of 7 mm. In some embodiments, the roofing shingle10has a thickness of 8 mm. In some embodiments, the roofing shingle10has a thickness of 9 mm. In some embodiments, the roofing shingle10has a thickness of 10 mm.

In some embodiments, the roofing shingle10includes a structure, composition, components, and/or function similar to those of one or more embodiments of the photovoltaic modules disclosed in U.S. Patent Application Publication No. 2022/0393637, published Dec. 8, 2022, entitled “Roofing Module System,” owned by GAF Energy LLC, the contents of which are incorporated by reference herein in its entirety.

Referring toFIG.3, in some embodiments, the roofing shingle10includes a first core layer12aand a second core layer12b.In some embodiments, the first core layer12ais juxtaposed with the cap layer14. In some embodiments, the second core layer12bis juxtaposed with the first core layer12a.In some embodiments, the first core layer12aand the second core layer12bare welded to one another. In some embodiments, the first core layer12aand the second core layer12bare ultrasonically welded to one another. In some embodiments, the first core layer12aand the second core layer12bare heat welded to one another. In some embodiments, the first core layer12aand the second core layer12bare thermally bonded to one another. In some embodiments, the first core layer12aand the second core layer12bare adhered to one another by an adhesive. In some embodiments, the first core layer12aand the second core layer12bare laminated. In some embodiments, the first core layer12aand the second core layer12bare co-extruded. In some embodiments, the first core layer12aand the second core layer12bare mechanically attached to one another. In some embodiments, the first core layer12aand the second core layer12bare attached to one another by at least one fastener. In some embodiments, the first core layer12aand the second core layer12bare attached to one another by a plurality of fasteners. In some embodiments, the first core layer12aand the second core layer12bare attached to one another by deforming one of the first core layer12aand the second core layer12binto the other one of the first core layer12aand the second core layer12b.In some embodiments, the first core layer12aand the second core layer12bare attached to one another by deforming a portion of one of the first core layer12aand the second core layer12binto the other one of the first core layer12aand the second core layer12b.In some embodiments, the first core layer12aand the second core layer12bare attached to one another by forming at least one hole in one or both of the first core layer12aand the second core layer12band dispensing molten material into the at least one hole to connect the first core layer12aand the second core layer12b.In some embodiments, non-limiting examples of fasteners, fastening means and methods for fastening, connecting and attaching the first core layer12ato the second core layer12bare disclosed in U.S. Pat. No. 7,833,371 to Binkley et al, U.S. Pat. No. 8,006,457 to Binkley et al, U.S. Pat. No. 8,127,514 to Binkley et al, and U.S. Pat. No. 8,316,608 to Binkley et al, each of which is incorporated by reference herein in its entirety.

Referring toFIG.4, in some embodiments, a plurality of the roofing shingles10is installed on a roof deck50. In some embodiments, the extended portion35of a first one10aof the roofing shingles10overlays the side lap32of a second one10bof the roofing shingles10. In some embodiments, the first end16of the core layer12of the first roofing shingle10ais juxtaposed with the second end18of the core layer12of the second roofing shingle10b.In some embodiments, the first end24of the cap layer14of the first roofing shingle10ais juxtaposed with the second end26of the cap layer14of the second roofing shingle10b.In some embodiments, a seam43is located between the first end24of the cap layer14of the first roofing shingle10aand the second end26of the cap layer14of the second roofing shingle10b.In some embodiments, the seam43is sealed. In some embodiments, the seam43is sealed with a sealant. In some embodiments, the seam43is sealed with an adhesive sealant. In some embodiments, the seam43is sealed with tape. In some embodiments, the tape is butyl tape.

Referring toFIG.5, in some embodiments, an offset of the core layer12from the cap layer14forms the side lap32and a side lap33. In some embodiments, the first end16of the core layer12is offset from the first end24of the cap layer14. In some embodiments, the first end16of the core layer12extends outwardly relative to the first end24of the cap layer14. In some embodiments, the second end18of the core layer12is offset from the second end26of the cap layer14. In some embodiments, the second end18of the core layer12extends outwardly relative to the second end26of the cap layer14. In some embodiments, the first end16of the core layer12is offset from the first end24of the cap layer14by a length L6. In some embodiments, the second end18of the core layer12is offset from the second end26of the cap layer14by a length L7. In some embodiments, the length L6is 1 inch to 10 inches. In some embodiments, the length L7is 1 inch to 10 inches. In some embodiments, the length L6and the length L7may each be in the same ranges as described above for the length L2.

FIG.6illustrates some embodiments of manufacturing the roofing shingle10. In some embodiments, the roofing shingle10is processed by a roll-to-roll (R2R) process. In some embodiments, the core layer12is driven by a first roller52and the cap layer14is driven by a second roller54. In some embodiments, a longitudinal axis of the first roller52is parallel with a longitudinal axis of the second roller54. In some embodiments, a longitudinal axis of the first roller52is substantially parallel with a longitudinal axis of the second roller54. In some embodiments, the first roller52is offset from the second roller54. In some embodiments, the first roller52is offset from the second roller54by the length L1. In some embodiments, the core layer12and the cap layer14are simultaneously and continuously driven in a machine direction by the respective first and second rolls52,54. In some embodiments, the cap layer14is attached to the core layer14in an area A. In some embodiments, the core layer12and the cap layer14are welded to one another. In some embodiments, the core layer12and the cap layer14are ultrasonically welded to one another. In some embodiments, the core layer12and the cap layer14are heat welded to one another. In some embodiments, the core layer12and the cap layer14are thermally bonded to one another. In some embodiments, the core layer12and the cap layer14are adhered to one another by an adhesive. In some embodiments, the core layer12and the cap layer14are laminated. In some embodiments, the core layer12and the cap layer14are mechanically attached to one another. In some embodiments, the core layer12and the cap layer14are attached to one another by at least one fastener. In some embodiments, the core layer12and the cap layer14are attached to one another by a plurality of fasteners. In some embodiments, the core layer12and the cap layer14are attached to one another by deforming one of the core layer12and the cap layer14into the other one of the core layer12and the cap layer14. In some embodiments, the core layer12and the cap layer14are attached to one another by deforming a portion of one of the core layer12and the cap layer14into the other one of the core layer12and the cap layer14. In some embodiments, the core layer12and the cap layer14are attached to one another by forming at least one hole in one or both of the core layer12and the cap layer14and dispensing molten material into the at least one hole to connect the core layer12and the cap layer14. In some embodiments, non-limiting examples of fasteners, fastening means and methods for fastening, connecting and attaching the core layer12and the cap layer14are disclosed in U.S. Pat. No. 7,833,371 to Binkley et al, U.S. Pat. No. 8,006,457 to Binkley et al, U.S. Pat. No. 8,127,514 to Binkley et al, and U.S. Pat. No. 8,316,608 to Binkley et al, each of which is incorporated by reference herein in its entirety.

Referring toFIGS.7A,7B and8, in some embodiments, a pattern40is formed on a first surface42of the cap layer14. In some embodiments, the pattern40is formed on the first surface42of reveal portion38of the cap layer14. In some embodiments, when the roofing shingle10is installed on the roof deck50of a structure, the pattern40is viewable from the vantage point of an individual located at a ground level of the structure.

In some embodiments, the first surface42of the roofing shingle10is textured. In some embodiments, the first surface42of the roofing shingle10is textured to impart an appearance of a traditional asphalt roofing shingle. In some embodiments, the first surface42of the roofing shingle10is textured to impart an appearance of and aesthetically match a photovoltaic module100(seeFIG.12). In some embodiments, the photovoltaic module100includes at least one solar cell102. In some embodiments, the photovoltaic module100includes a plurality of the solar cells102. In some embodiments, the photovoltaic module100includes a structure, composition, components, and/or function similar to those of one or more embodiments of the photovoltaic modules disclosed in PCT International Patent Publication No. WO 2022/051593, Application No. PCT/US2021/049017, published Mar. 10, 2022, entitled “Building Integrated Photovoltaic System,” owned by GAF Energy LLC, the contents of which are incorporated by reference herein in its entirety.

In some embodiments, the first surface42is an embossed surface. In some embodiments, the pattern40on the first surface42includes a plurality of indentations. In some embodiment, each of the plurality of indentations has a circular shape. In some embodiment, each of the plurality of indentations has a rectangular shape. In some embodiments, each of the plurality of indentations has a square shape. In some embodiments, each of the plurality of indentations has a triangular shape. In some embodiments, each of the plurality of indentations has an elliptical shape. In some embodiments, each of the plurality of indentations has an oval shape. In some embodiments, each of the plurality of indentations has a rhombus shape. In some embodiments, each of the plurality of indentations has a hexagonal shape. In some embodiments, each of the plurality of indentations includes a pentagonal shape. In some embodiments, each of the plurality of indentations has a polygonal shape. In some embodiments, each of the plurality of indentations has a non-polygonal shape. In some embodiments, each of the plurality of indentations has a geometric shape. In some embodiments, each of the plurality of indentations has a non-geometric shape. In some embodiments, the pattern40on the first surface42includes a plurality of dimples. In some embodiments, the indentations are created by embossing a portion of the first surface42. In some embodiments, the texture includes a surface roughness (Ra). In some embodiments, the surface roughness (Ra) is 1 micron to 200 microns. In some embodiments, the pattern40on the first surface42includes a plurality of lines. In some embodiments, the pattern40on the first surface42includes a plurality of grooves. In some embodiments, the pattern40on the first surface42includes cross-hatches.

In some embodiments, a pattern roller44forms the pattern40on the first surface42of the cap layer14. In some embodiments, the pattern roller44includes a circumferential face46. In some embodiments, the face46includes at least one pattern. In some embodiments, the at least one pattern includes a plurality of patterns. In some embodiments, the plurality of patterns are strips45along a length of the roller44in a longitudinal direction. In some embodiments, the plurality of patterns includes at least two patterns. In some embodiments, the plurality of patterns includes at least three patterns. In some embodiments, the plurality of patterns includes at least four patterns. In some embodiments, the plurality of patterns includes at least five patterns. In some embodiments, the plurality of patterns includes at least six patterns. In some embodiments, each of the plurality of patterns is identical to one another. In some embodiments, each of the plurality of patterns is different from one another. In some embodiments, at least one of the plurality of patterns is different from at least another one of the patterns. In some embodiments, at least one of the plurality of patterns is similar to at least another one of the patterns. In some embodiments, the pattern roller44has a circumference of 68.5 inches and a diameter of 21.8 inches. In some embodiments, the pattern roller44includes four patterns. In some embodiments, each of the patterns extends for 17-⅛ inches along the circumference of the pattern roller44. In some embodiments, the pattern roller44has a greater or lower circumference than 68.5 inches and a corresponding lower or greater diameter.

In some embodiments, the pattern40is formed simultaneously with the processing of the core layer12and the cap layer14of the roofing shingle10. In some embodiments, the pattern40processed during a roll-to-roll (R2R) process of the core layer12and the cap layer14.

In some embodiments, the pattern is printed on the first surface42of the cap layer14. In some embodiments, a pattern or depiction of solar cells is printed on the first surface42of the cap layer14. In some embodiments, each of the depicted solar cells has a width of 5 inches to 8 inches. In some embodiments, the pattern is printed on the first surface42of the cap layer14by ink jet printing. In some embodiments, the pattern is printed on the first surface42of the cap layer14by laser printing. In some embodiments, the pattern is printed on the first surface42of the cap layer14by lithography. In some embodiments, the pattern is printed on the first surface42of the cap layer14by flexography. In another embodiment, the cap layer14is painted. In another embodiment, the cap layer14is a colored layer. In another embodiment, the cap layer14includes a black color. In some embodiments, the color of the cap layer14includes a mixture of colors. In some embodiments, the cap layer14includes an infrared reflective pigment. In some embodiments, the infrared reflective pigment includes graphene. In some embodiments, the roofing shingle10meets standards of California Building Energy Efficiency Standards of Residential and Nonresidential Buildings, Title 24, Part 6.

In some embodiments, the cap layer14includes magnesium oxide (MgO). In some embodiments, the cap layer14includes 35% to 50% by weight of MgO. In some embodiments, the cap layer14includes 35% to 45% by weight of MgO. In some embodiments, the cap layer14includes 35% to 40% by weight of MgO. In some embodiments, the cap layer14includes 40% to 50% by weight of MgO. In some embodiments, the cap layer14includes 40% to 45% by weight of MgO. In some embodiments, the cap layer14includes 45% to 50% by weight of MgO. In some embodiments, the cap layer14includes 35% by weight of MgO. In some embodiments, the cap layer14includes 40% by weight of MgO. In some embodiments, the cap layer14includes 45% by weight of MgO. In some embodiments, the cap layer14includes 50% by weight of MgO.

In some embodiments, the cap layer14includes ketone ethylene ester (KEE) In some embodiments, the cap layer14includes a PVC-KEE hybrid membrane. In some embodiments, the roofing shingle10is adapted to be a component of a photovoltaic system that includes a fire resistance that conforms to standards under UL 790/ASTM E 108 test standards. In some embodiments, the roofing shingle10includes a Class A rating when tested in accordance with UL 790/ASTM E 108.

FIG.9illustrates some embodiments of manufacturing the roofing shingle10. In some embodiments, the core layer12is driven by a bottom infeed roller152and the cap layer14is driven by a top infeed roller154. In some embodiments, a longitudinal axis of the bottom infeed roller152is parallel with a longitudinal axis of the top infeed roller154. In some embodiments, a longitudinal axis of the bottom infeed roller152is substantially parallel with a longitudinal axis of the top infeed roller154. In some embodiments, the bottom infeed roller152is offset from the top infeed roller154. In some embodiments, the top infeed roller154is offset from the bottom infeed roller152by the length L1in a direction along the longitudinal axis of the bottom infeed roller152. In some embodiments, the core layer12and the cap layer14are simultaneously and continuously driven in a machine direction by the respective one of the bottom infeed roller152and the top infeed roller154. In some embodiments, a pattern roller144is located proximate to the bottom infeed roller152. In some embodiments, the pattern40is formed simultaneously with the processing of the core layer12and the cap layer14of the roofing shingle10.

Referring toFIG.10, in some embodiments, the pattern40includes at least one row R of a depiction of a plurality of solar cells48. In some embodiments, the at least one row R includes a plurality of the rows R. In some embodiments, each of the rows R extends from the first end24to the second end26of the cap layer14. In some embodiments, the depiction of the solar cells48includes at least one first cell A and at least one second cell B. In some embodiments, the at least one first cell A includes a plurality of the first cells A. In some embodiments, the at least one second cell B includes a plurality of the second cells B. In some embodiments, each of the cells A has a first color. In some embodiments, each of the cells B has a second color. In some embodiments, the second color is darker than the first color. In some embodiments, the second color is lighter than the first color. In some embodiments, each of the rows R has a repeating pattern of a pair of the first cells A and a pair of the second cells B (e.g., AABBAABB . . . ). In some embodiments, each of the rows R has a repeating pattern of a first cell A and a second cell B (e.g., ABABAB . . . ). In some embodiments, each of the rows R has a repeating pattern of three of the first cell A and three of the second cell B (e.g., AAABBBAAABBB . . . ). In some embodiments, each of the rows R has a repeating pattern of more than three of the first cell A and more than three of the second cell B (e.g., AAAABBBBAAAABBBB . . . ; AAAAABBBBBAAAAABBBBB . . . etc.). In some embodiments, each of the rows R are spaced apart from one another. In some embodiments, at least one smooth portion49is located between a corresponding pair of the rows R. In some embodiments, the at least one smooth portion49includes a plurality of the smooth portions49. In some embodiments, the at least one smooth portion49extends from the first end24to the second end26of the cap layer14.

FIG.11illustrates some embodiments of manufacturing the roofing shingle10. In some embodiments, the core layer12is driven by a first infeed roller252and the cap layer14is driven by a second infeed roller254. In some embodiments, a longitudinal axis of the first infeed roller252is parallel with a longitudinal axis of the second infeed roller254. In some embodiments, a longitudinal axis of the first infeed roller252is substantially parallel with a longitudinal axis of the second infeed roller254. In some embodiments, the first infeed roller252is offset from the second infeed roller254. In some embodiments, the first infeed roller252is offset from the second infeed roller254by the length L1in a direction along the longitudinal axis of the second infeed roller254. In some embodiments, the core layer12and the cap layer14are simultaneously and continuously driven in a machine direction by the respective one of the first infeed roller252and the second infeed roller254. In some embodiments, the pattern40is formed simultaneously with the processing of the core layer12and the cap layer14of the roofing shingle10. In some embodiments, the pattern40is formed by a press die255. In some embodiments, the press die255is located downstream from the rollers252,254. In some embodiments, the pattern40is stamped within the cap layer14by the press die255. In some embodiments, the pattern40is stamped on the cap layer14by the press die255.

In some embodiments, a roofing system includes at least one of the roofing shingle10and at least one photovoltaic module100. In some embodiments, the at least one of the roofing shingle10includes a plurality of roofing shingles10. In some embodiments, the at least one photovoltaic module100includes a plurality of photovoltaic modules100. In some embodiments, the at least one photovoltaic module100is electrically active. In some embodiments, the system includes at least one roofing shingle10and at least one electrically active photovoltaic module100. In some embodiments, the system includes at least one roofing shingle10, at least one electrically active photovoltaic module100, and at least one nonactive photovoltaic module100. In some embodiments, the at least one roofing shingle10and the at least one photovoltaic module100are installed on a roof deck. In some embodiments, the appearance of the at least one roofing shingle10aesthetically matches the appearance of the at least one photovoltaic module100. As used herein, the term “aesthetically matches” means having a similar overall visual appearance, texture, gloss, and/or color, and with respect to an embodiment of the roofing shingle10, the roofing shingle10includes a visual appearance, texture, gloss, and/or color that is similar to those of the photovoltaic module100. In some embodiments, the color is measured under a CIELAB color space system. In some embodiments, the gloss can be quantified in accordance with the ASTM E430 Standard Test Methods for Measurement of Gloss of High-Gloss Surfaces by Abridged Goniophotometry. In some embodiments, the appearance of each of the roofing shingle10and the photovoltaic module100are visually perceptible by and subjective to a human.

In some embodiments, the roofing shingle10is cuttable. In some embodiments, the roofing shingle10is cuttable to a desired size and shape. As used herein, the term “cuttable” means capable of being cut or penetrated with or as if with by an edged instrument, and with respect to certain embodiments of the roofing shingle10, the roofing shingle10is capable of being cut or penetrated by am edged instrument such as a cutting knife, scissors, razor, or other suitable roofing module cutting instruments and tools. In some embodiments, the roofing shingle10is configured to be installed on the roof deck50. In some embodiments, the roofing shingle10is configured to be installed on non-solar roof planes of the roof deck50. In some embodiments, the roofing shingle10is configured to be installed either partially or fully around an array of the photovoltaic modules100. In some embodiments, the roofing shingle10is cuttable to a size and shape for positioning around obstacles, such as vents, chimneys, antennas, and other roofing structures. In some embodiments, the roofing shingle10cuttable to a size and shape to extend to roofing eaves and ridges.

In some embodiments, a method includes the steps of:obtaining a plurality of the roofing shingles10;obtaining a plurality of photovoltaic modules100, each of the plurality of photovoltaic modules100includes at least one solar cell;installing the plurality of photovoltaic modules100on the roof deck50;installing the plurality of roofing shingles10on the roof deck50proximate to the plurality of photovoltaic modules100, such that the extended portion35of the first roofing shingle10aof the plurality of roofing shingles10overlays the side lap32of the second roofing shingle10bof the plurality of roofing shingles10, each of the roofing shingles10a,10baesthetically matches the photovoltaic modules100.

In some embodiments, a method includes the steps of:obtaining the core layer12of a first material;obtaining the cap layer14of a second material;positioning the second end26of the cap layer14offset from the second end18of the core layer12and positioning the first end24of the cap layer14offset from the first end16of the core layer12;overlaying the cap layer14over the core layer12; andattaching the cap layer14to the core layer12to form at least one of the roofing shingle10.