Patent ID: 12227947

DETAILED DESCRIPTION

The embodiments of the present disclosure will now be described in more detail with reference to the attached drawing figures.

FIGS.1A-6Cshow embodiments of shingles, including cap shingles, to roofing systems employing shingles such cap shingles, and methods of forming cap shingles according to the present disclosure.

FIG.1Ais a top view showing an example embodiment of a shingle, for example a ridge, hip, or cap shingle10, manufactured according to principles of the present disclosure. In embodiments, the cap shingle10can include one or more layers of a shingle material. For example, in some embodiments, the cap shingle10can comprise a laminated structure including a first or top layer11of a shingle material, along which an exposure portion12and a headlap portion13are defined; and a second or bottom layer14of shingle material (FIGS.1B and3A) that is attached to the top layer11(e.g., by adhesives, welding, etc. . . . ) to form the multi-layer cap shingle10.

As shown inFIG.2, in embodiments, the cap shingles10can be configured for installation on a roof R, in particular being positioned over and along a ridge6, hip or cap of the roof R as part of a roofing system5. It will also be understood that the roofing system5may include other roofing materials, including, but not limited to, other types of shingles, roofing membranes, tiles, decking materials.

In embodiments, the cap shingles10illustrated in the figures are configured to be positioned over a roof deck7or roofing substrate of the roof. In embodiments, the roof deck can include sheathing, wood, oriented strand board, or other decking materials. In addition, in embodiments, a plurality of shingles, tiles, panels, roofing membranes, an underlayment, or other roofing material, or combinations thereof, can be applied along the roof deck,

In embodiments, the cap shingles will be configured to be installed along a ridge, hip or cap of a roof such as by being placed along and over the ridge6, hip or cap of the roof R, arranged in an overlapping relationship along a ridgeline direction RD of the roof, and with first and second side edges16and18of the cap shingles10extending over an upper surface8of the roof deck7of the roof. In embodiments, such as indicated inFIG.2, the cap shingles can be bent in an arc along a longitudinal axis9extending in the ridgeline direction RD of the roof for installation over the ridge6, hip, or cap of the roof. The cap shingles can be secured to the roof deck7, to adjacent cap shingles, and/or to other roofing materials, such as adjacent roofing shingles, tiles, panels, roofing membranes, an underlayment, decking materials, or combinations thereof, by adhesives or sealant materials, mechanical attachments such as fasteners, connectors, or other attachments, or combinations thereof.

In embodiments, the roof R, such as shown inFIG.2, can be configured to form a sloped roof (e.g., such as a residential roof), with the roof deck7thereof having a slope or pitch of Y:X. For example, in some embodiments, the roof can include a steep slope roof having a slope in a ratio of 4:12 to 12:12, where Y corresponds to the “rise” of the roof, and where X corresponds to the “run” of the roof. In some embodiments, the roof can have a slope in a ratio of 5:12 to 12:12; 6:12 to 12:12; 7:12 to 12:12; 8:12 to 12:12; 9:12 to 12:12; 10:12 to 12:12; or 11:12 to 12:12. Other slopes also can be provided.

In other embodiments, the roof deck7can be configured to form a lower slope roof, including a low slope roof having a slope or pitch in a ratio of less than 4:12; less than 3:12; less than 2:12; less than 1:12; or in a ratio of 1:12 to 4:12; a ratio of 1:12 to 3:12; a ratio of 1:12 to 2:12; a ratio of 2:12 to 4:12; a ratio of 2:12 to 3:12; or a ratio of 3:12 to 4:12. Other slopes also can be provided.

As shown inFIG.2, in an example embodiment, the roof R can have a ridge6, hip, or cap that extends along the roof in a ridgeline direction along which a plurality of cap shingles10can be positioned, and with the roof deck7extending downwardly at an angle from the ridge6to an eave8of the roof. The roof further generally will include a plurality of roofing shingles5applied over and covering the roof deck7. In some embodiments, the roof R also could include features such as, dormers, gables, and/or other features. In other embodiments, the roof R could be any suitable style of roof, including a roof configured with one or more ridges and/or one or more hips.

In embodiments, the shingles can comprise cap shingles10such as shown inFIGS.1A and1B, where the cap shingles are configured to withstand exposure to weather, including exposure to wind, rain, snow, extreme temperatures (e.g., above 100° F.) and extreme cold (e.g., below 0° F.). The cap shingles, when installed along a ridge hip or cap of a roof, will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to 116 mph [187 km/h] (Class D in ASTM D7158); in some embodiments, the cap shingles will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to 155 mph [249 km/h] (Class G in ASTM D7158); and in other embodiments, the cap shingles will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to 194 mph [312 km/h] (Class H in ASTM D7158), when tested in accordance with ASTM D3161 (the Standard Test Method for Wind Resistance of Steep Slope Roofing Products (Fan-Induced Method)) and/or ASTM D7158 (the Standard Test Method for Wind Resistance of Sealed Asphalt Shingles (Uplift Force/Uplift Resistance Method).

In addition, in embodiments, the cap shingles can have an increased mechanical uplift resistance measured in accordance with ASTM D6381. For example, in embodiments, when installed along a ridge, hip or cap of a roof, as shown inFIG.2, the cap shingles can have a maximum load mechanical uplift resistance that is greater than 20 lbf, and in embodiments, can have a maximum load mechanical uplift resistance of 26 lbf to 38 lbf and an average maximum load mechanical uplift resistance of 27 lbf to 32 lbf.

In embodiments, the cap shingles can have a maximum load mechanical uplift resistance of 22 lbf to 40 lbf, 22 lbf to 39 lbf, 22 lbf to 38 lbf, 22 lbf to 37 lbf, 22 lbf to 36 lbf, 22 lbf to 35 lbf, 22 lbf to 34 lbf, 22 lbf to 33 lbf, 22 lbf to 32 lbf, 22 lbf to 31 lbf, 22 lbf to 30 lbf, 22 lbf to 29 lbf, 22 lbf to 28 lbf, 22 lbf to 27 lbf, 22 lbf to 26 lbf, 22 lbf to 25 lbf, 22 lbf to 24 lbf, 22 lbf to 23 lbf, 23 lbf to 40 lbf, 23 lbf to 39 lbf, 23 lbf to 38 lbf, 23 lbf to 37 lbf, 23 lbf to 36 lbf, 23 lbf to 35 lbf, 23 lbf to 34 lbf, 23 lbf to 33 lbf, 23 lbf to 32 lbf, 23 lbf to 31 lbf, 23 lbf to 30 lbf, 23 lbf to 29 lbf, 23 lbf to 28 lbf, 23 lbf to 27 lbf, 23 lbf to 26 lbf, 23 lbf to 25 lbf, 23 lbf to 24 lbf, 24 lbf to 40 lbf, 24 lbf to 39 lbf, 24 lbf to 38 lbf, 24 lbf to 37 lbf, 24 lbf to 36 lbf, 24 lbf to 35 lbf, 24 lbf to 34 lbf, 24 lbf to 33 lbf, 24 lbf to 32 lbf, 24 lbf to 31 lbf, 24 lbf to 30 lbf, 24 lbf to 29 lbf, 24 lbf to 28 lbf, 24 lbf to 27 lbf, 24 lbf to 26 lbf, 24 lbf to 25 lbf, 25 lbf to 40 lbf, 25 lbf to 39 lbf, 25 lbf to 38 lbf, 25 lbf to 37 lbf, 25 lbf to 36 lbf, 25 lbf to 35 lbf, 25 lbf to 34 lbf, 25 lbf to 33 lbf, 25 lbf to 32 lbf, 25 lbf to 31 lbf, 25 lbf to 30 lbf, 25 lbf to 29 lbf, 25 lbf to 28 lbf, 25 lbf to 27 lbf, 25 lbf to 26 lbf, 26 lbf to 40 lbf, 26 lbf to 39 lbf, 26 lbf to 38 lbf, 26 lbf to 37 lbf, 26 lbf to 36 lbf, 26 lbf to 35 lbf, 26 lbf to 34 lbf, 26 lbf to 33 lbf, 26 lbf to 32 lbf, 26 lbf to 31 lbf, 26 lbf to 30 lbf, 26 lbf to 29 lbf, 26 lbf to 28 lbf, 26 lbf to 27 lbf, 27 lbf to 40 lbf, 27 lbf to 39 lbf, 27 lbf to 38 lbf, 27 lbf to 37 lbf, 27 lbf to 36 lbf, 27 lbf to 35 lbf, 27 lbf to 34 lbf, 27 lbf to 33 lbf, 27 lbf to 32 lbf, 27 lbf to 31 lbf, 27 lbf to 30 lbf, 27 lbf to 29 lbf, 27 lbf to 28 lbf, 28 lbf to 40 lbf, 28 lbf to 39 lbf, 28 lbf to 38 lbf, 28 lbf to 37 lbf, 28 lbf to 36 lbf, 28 lbf to 35 lbf, 28 lbf to 34 lbf, 28 lbf to 33 lbf, 28 lbf to 32 lbf, 28 lbf to 31 lbf, 28 lbf to 30 lbf, 28 lbf to 29 lbf, 29 lbf to 40 lbf, 29 lbf to 39 lbf, 29 lbf to 38 lbf, 29 lbf to 37 lbf, 29 lbf to 36 lbf, 29 lbf to 35 lbf, 29 lbf to 34 lbf, 29 lbf to 33 lbf, 29 lbf to 32 lbf, 29 lbf to 31 lbf, 29 lbf to 30 lbf, 30 lbf to 40 lbf, 30 lbf to 39 lbf, 30 lbf to 38 lbf, 30 lbf to 37 lbf, 30 lbf to 36 lbf, 30 lbf to 35 lbf, 30 lbf to 34 lbf, 30 lbf to 33 lbf, 30 lbf to 32 lbf, 30 lbf to 31 lbf, 31 lbf to 40 lbf, 31 lbf to 39 lbf, 31 lbf to 38 lbf, 31 lbf to 37 lbf, 31 lbf to 36 lbf, 31 lbf to 35 lbf, 31 lbf to 34 lbf, 31 lbf to 33 lbf, 31 lbf to 32 lbf, 32 lbf to 40 lbf, 32 lbf to 39 lbf, 32 lbf to 38 lbf, 32 lbf to 37 lbf, 32 lbf to 36 lbf, 32 lbf to 35 lbf, 32 lbf to 34 lbf, 32 lbf to 33 lbf, 33 lbf to 40 lbf, 33 lbf to 39 lbf, 33 lbf to 38 lbf, 33 lbf to 37 lbf, 33 lbf to 36 lbf, 33 lbf to 35 lbf, 33 lbf to 34 lbf, 34 lbf to 40 lbf, 34 lbf to 39 lbf, 34 lbf to 38 lbf, 34 lbf to 37 lbf, 34 lbf to 36 lbf, 34 lbf to 35 lbf, 35 lbf to 40 lbf, 35 lbf to 39 lbf, 35 lbf to 38 lbf, 35 lbf to 37 lbf, 35 lbf to 36 lbf, 36 lbf to 40 lbf, 36 lbf to 39 lbf, 36 lbf to 38 lbf, 36 lbf to 37 lbf, 37 lbf to 40 lbf, 37 lbf to 39 lbf, 37 lbf to 38 lbf, 38 lbf to 40 lbf, 38 lbf to 39 lbf, or 39 lbf to 40 lbf.

In embodiments, each cap shingle10includes at least one layer of shingle material and can include a coating15(FIG.1B) that can comprise an asphalt material applied to at least one surface of the shingle material. In some embodiments, the cap shingle10can be made with a single layer fabric; and in other embodiments, the cap shingle10can be made with more than one layer, e.g., including a first layer of shingle material and with a second layer of shingle material. In embodiments, the cap shingle also can include additional layers applied to the first or second layer. For example, the cap shingles10can include a laminated, double-layer fabric shingle material.

As further indicated inFIGS.1A and1B, in embodiments, the cap shingle10can have a plurality of peripheral edges, including a first side edge16, a second side edge18, a front edge20, and a back edge22. The cap shingle10further can include an upper surface24(FIG.1A) with the exposure portion12and the headlap portion13defined therealong, and a lower surface26opposite the upper surface. In embodiments, the upper surface24of the cap shingle can have a granulated surface or appearance. For example, in embodiments, the upper surface24of the cap shingle10can include a plurality of protective granules applied along at least a part of the upper surface of each cap shingle. In embodiments, a plurality of granules can be applied along the headlap and exposure portions of each cap shingle. In embodiments, a first plurality of granules can be applied to the exposure portion12(e.g., butt granules17A), and can be different (e.g., different in size, color, reflectivity, cost etc.) from a second plurality of granules (e.g., headlap granules17B) applied to the headlap portion13. In embodiments the granules applied to the headlap and exposure portions can be the same; and in some embodiments the granules can be applied to the headlap portion13and exposure portion in different amounts.

In some embodiments, the upper surface of each cap shingle also can incorporate additional materials for protection against exposure to weather (e.g., wind, rain, snow, heat, cold, sunlight (including ultraviolet (UV) light, visible light, infrared (IR) light), hail and other impacts, etc. . . . ), and/or to provide an aesthetic appearance. In embodiments, the headlap portion13will be adjacent or proximate the back edge22of the cap shingle, and can be configured to be overlapped by at least one additional cap shingle10or other roofing shingle arranged along the roof, e.g., by an exposure portion12of a next or adjacent cap shingle, the exposure portion of each cap shingle being configured to be exposed to weather.

FIG.1Bis a view of an embodiment of a bottom layer14of a cap shingle10ofFIG.1A. In this example embodiment, as shown in inFIG.1B, the bottom layer14can include a slot19extending from its front edge20rearward along a lower surface26of the cap shingle. The slot19can act as a deformation mechanism that is configured to enable deformation and flexing of the bottom layer14of the cap shingle as the cap shingle is bent along it longitudinal axis9extending in the ridgeline direction RD (FIG.2) of the roof for fitting over the ridge, hip or cap of the roof. In embodiments, the slot19can enable the bottom layer to narrow as the cap shingle10is bent around a ridge, hip, or cap of the roof to help maintain an alignment of the side edges of the layers of the cap shingle10. The bottom layer14could be otherwise configured without departing from the present disclosure.

In embodiments, a sealant30can be applied along the lower surface26of each cap shingle. For example, in embodiments, the sealant30can be positioned adjacent the forward edge20of the cap shingle. In addition, in embodiments, a releasable covering material, such as a release tape31or other, similar material, can be applied along the bottom layer14adjacent the rear edge22of the cap shingle, the releasable covering material being configured to cover and protect the sealant when the cap shingles are stacked and prior to installation.

In embodiments, the sealant30can comprise one or more strips33of a self-sealing material that, in embodiments as shown inFIG.1B, can be applied along the bottom layer14adjacent the front or forward edge20of the cap shingle. In some embodiments, the strips33of self-sealing material can include dashes, dots, continuous or discontinuous lines of sealant material or combinations thereof. In addition, in embodiments, the strips33of self-sealing material can be applied in various patterns; for example, using different combinations and/or arrangements of sealant, with gaps or spaces, such as to enable drainage of moisture. Still further, in some embodiments, different sealant materials, including sealant materials with different properties, can be used.

In embodiments, the strips33of self-sealing material further will be configured to adhere the cap shingle10to an underlying cap shingle (e.g., along the sealant attachment zone of the underlying cap shingle) when installed on a roof. For example, the one or more strips33of self-sealing material can be applied along the bottom layer14in positions near the front or forward edge20of the bottom layer14to adhere the cap shingle10to the headlap portion13of an adjacent underlying cap shingle10(FIGS.3A-4B). In some embodiments, the one or more strips33of self-sealing material also can be applied at other locations along the lower surface14. According to embodiments, the strips33of self-sealing sealant material can include sealing materials that can be activated by pressure, ambient and/or solar heating and/or by other factors.

In exemplary embodiments, the cap shingles10can be stacked for storage, transportation, etc. in bundles or pairs arranged to facilitate even stacking of the cap shingles. For example, the cap shingles10can be arranged with the lower surfaces26thereof facing one another (e.g., back to back) and with opposing orientations (e.g., so that the front edge20of one cap shingle10is generally aligned with the rear edge22of another cap shingle10). The strip of releasable material of one cap shingle10can be aligned with the sealant30of an adjacent cap shingle10in each pair of cap shingles of the stack so that the strip31of releasable covering material can protect the sealant30of the adjacent cap shingle and can help prevent bonding between the paired cap shingles during storage, transportation, etc. Accordingly, this arrangement of cap shingles10is adapted to provide for easy release of the cap shingles from their stacked arrangement in the bundle.

As shown inFIGS.1A,3B, and4A, in embodiments, a sealant attachment zone41can be formed along the upper surface of the cap shingle10between the headlap and exposure portions. For example, in embodiments, the sealant attachment zone41can be positioned in front of the headlap portion13along and/or proximate to the exposure portion12. In embodiments, the sealant attachment zone41can extend from the first side edge16toward the second side edge18of the cap shingle (e.g., transverse to the ridgeline direction RD (FIGS.1A and2) substantially across the width of the cap shingle10.

In the illustrated embodiments, the sealant attachment zone41(FIGS.1A and4B) can have a front edge43and a rear edge45. In embodiments, the front edge43can extend along and/or proximate to the exposure portion12(e.g., along a rear edge12A thereof), and the rear edge45can be spaced from the exposure portion12and from the rear edge22of the cap shingle10, and can define a forward edge13A of the headlap portion13. Alternatively, the sealant attachment zone41could be otherwise located adjacent or along the headlap portion13without departing from the disclosure. In embodiments, the sealant attachment zone41can be considered to be positioned between the headlap portion13and the exposure portion12.

In exemplary embodiments, the sealant attachment zone41can be configured for promoting more direct bonding between the sealant30(e.g., the strips33of self-sealing sealant material) of an adjacent overlapping cap shingle10A (FIGS.2-4B) and the asphaltic coating along the upper surface of the cap shingle10. In embodiments, the sealant attachment zone41can include a surfacing media46configured to promote adhesion between the upper surface24of the cap shingle10and the sealant of a next cap shingle installed along the ridge, hip, or cap of the roof. For example, in embodiments, the surfacing media46can include various materials selected to help increase the contact area between the strips33of self-sealing sealant material of an overlapping cap shingle10A and the asphalt coating15of the adjacent overlapped cap shingle10during installation of the cap shingles along the ridge, hip, or cap of a roof. In embodiments, the sealant attachment zone41is configured to facilitate a substantially direct asphalt to asphalt contact and enhanced adhesion between cap shingles10, and can provide increased asphalt to asphalt bonding between cap shingles10when installed.

In exemplary embodiments, the surfacing media46can include a plurality of particles applied over the asphaltic coating applied the upper surface24of the at least one layer of shingle material along the sealant attachment zone41. In embodiments, the particles of the surfacing media46can be suitable to provide sufficient surface coverage of the asphaltic coating of the top layer of shingle material11along the sealant attachment zone41so as to help reduce or substantially eliminate sticking of the sealant attachment zone41to other surfaces during manufacturing, transportation, storage, etc. of the cap shingle10. The surfacing media46of the sealant attachment zone thus generally will comprise a material selected to at least partially cover and protect an exposed portion of the asphaltic coating of the cap shingles along the sealant attachment zone, but which also will be adapted to facilitate a more direct engagement between the asphalt coating along the upper surface of a first or previously installed cap shingle and the sealant of a second or next cap shingle being installed thereover.

In embodiments, the sealant attachment zone41will comprise a size (e.g., a length and a width) configured to provide an increased contact area of the asphaltic coating of the cap shingle10adjacent the headlap portion13thereof to enhance more direct engagement and promote adhesion between the sealant (e.g., strips33of self-sealing material) of an overlapping cap shingle and the asphalt in the sealant attachment zone41when the cap shingles10are installed on a roof. In embodiments, the sealant attachment zone41can extend across a selected portion of the upper surface of the cap shingle, and in some embodiments can be formed in one or more sections across the upper surface of the cap shingle. Still further, in some embodiments, the sealant attachment zone can have a width (in the lateral direction across the cap shingle) that is substantially the same as the headlap portion of the cap shingle (e.g., as shown inFIGS.1A,3B and5A), and a length (in the longitudinal direction along the cap shingle) of 1 inch to 1 5/16thinches.

In addition, in embodiments, the sealant attachment zone can have a length of 1 inch to 3 inches, 1 inch to 2 15/16thinches, 1 inch to 2⅞thinches, 1 inch to 2 13/16thinches, 1 inch to 2¾thinches, 1 inch to 2 11/16thinches, 1 inch to 2⅝thinches, 1 inch to 2 9/16thinches, 1 inch to 2½ inches, 1 inch to 2 7/16thinches, 1 inch to 2⅜thinches, 1 inch to 2 5/16thinches, 1 inch to 2¼thinches, 1 inch to 2⅛thinches, 1 inch to 2 1/16thinches, 1 inch to 2 inches, 1 inch to 1 15/16thinches, 1 inch to 1⅞thinches, 1 inch to 1 13/16thinches, 1 inch to 1¾thinches, 1 inch to 1 11/16thinches, 1 inch to 1⅝thinches, 1 inch to 1 9/16thinches, 1 inch to 1½ inches, 1 inch to 1 7/16thinches, 1 inch to 1⅜thinches, 1 inch to 1 5/16thinches, 1 inch to 1¼thinches, 1 inch to 1 3/16thinches, 1 inch to 1⅛thinches, 1 inch to 1 1/16thinches, 1 1/16thinches to 3 inches, 1 1/16thinches to 2 15/16thinches, 1 1/16thinches to 2⅞thinches, 1 1/16thinches to 2 13/16thinches, 1 1/16thinches to 2¾thinches, 1 1/16thinches to 2 11/16thinches, 1 1/16thinches to 2⅝thinches, 1 1/16thinches to 2 9/16thinches, 1 1/16thinches to 2½ inches, 1 1/16thinches to 2 7/16thinches, 1 1/16thinches to 2⅜thinches, 1 1/16thinches to 2 5/16thinches, 1 1/16thinches to 2¼thinches, 1 1/16thinches to 2⅛thinches, 1 1/16thinches to 2 1/16thinches, 1 1/16thinches to 2 inches, 1 1/16thinches to 1 15/16thinches, 1 1/16thinches to 1⅞thinches, 1 1/16thinches to 1 13/16thinches, 1 1/16thinches to 1¾thinches, 1 1/16thinches to 1 11/16thinches, 1 1/16thinches to 1⅝thinches, 1 1/16thinches to 1 9/16thinches, 1 1/16thinches to 1½ inches, 1 1/16thinches to 1 7/16thinches, 1 1/16thinches to 1⅜thinches, 1 1/16thinches to 1 5/16thinches, 1 1/16thinches to 1¼thinches, 1¼thinches to 3 inches, 1¼thinches to 2 15/16thinches, 1¼thinches to 2⅞thinches, 1¼thinches to 2 13/16thinches, 1¼thinches to 2¾thinches, 1¼thinches to 2 11/16thinches, 1¼thinches to 2⅝thinches, 1¼thinches to 2 9/16thinches, 1¼thinches to 2½ inches, 1¼thinches to 2 7/16thinches, 1¼thinches to 2⅜thinches, 1¼thinches to 2 5/16thinches, 1¼thinches to 2¼thinches, 1¼thinches to 2⅛thinches, 1¼thinches to 2 1/16thinches, 1¼thinches to 2 inches, 1¼thinches to 1 15/16thinches, 1¼thinches to 1⅞thinches, 1¼thinches to 1 13/16thinches, 1¼thinches to 1¾thinches, 1¼thinches to 1 11/16thinches, 1¼thinches to 1⅝thinches, 1¼thinches to 1 9/16thinches, 1¼thinches to 1½ inches, 1¼thinches to 1 7/16thinches, 1¼thinches to 1⅜thinches, 1 5/16thinches to 3 inches, 1 5/16thinches to 2 15/16thinches, 1 5/16thinches to 2⅞thinches, 1 5/16thinches to 2 13/16thinches, 1 5/16thinches to 2¾thinches, 1 5/16thinches to 2 11/16thinches, 1 5/16thinches to 2⅝thinches, 1 5/16thinches to 2 9/16thinches, 1 5/16thinches to 2½ inches, 1 5/16thinches to 2 7/16thinches, 1 5/16thinches to 2⅜thinches, 1 5/16thinches to 2 5/16thinches, 1 5/16thinches to 2¼thinches, 1 5/16thinches to 2⅛thinches, 1 5/16thinches to 2 1/16thinches, 1 5/16thinches to 2 inches, 1 5/16thinches to 1 15/16thinches, 1 5/16thinches to 1⅞thinches, 1 5/16thinches to 1 13/16thinches, 1 5/16thinches to 1¾thinches, 1 5/16thinches to 1 11/16thinches, 1 5/16thinches to 1⅝thinches, 1 5/16thinches to 1 9/16thinches, 1 5/16thinches to 1½ inches, 1 5/16thinches to 1 7/16thinches, 1 5/16thinches to 1⅜thinches, 1⅜thinches to 3 inches, 1⅜thinches to 2 15/16thinches, 1⅜thinches to 2⅞thinches, 1⅜thinches to 2 13/16thinches, 1⅜thinches to 2¾thinches, 1⅜thinches to 2 11/16thinches, 1⅜thinches to 2⅝thinches, 1⅜thinches to 2 9/16thinches, 1⅜thinches to 2½ inches, 1⅜thinches to 2 7/16thinches, 1⅜thinches to 2⅜thinches, 1⅜thinches to 2 5/16thinches, 1⅜thinches to 2¼thinches, 1⅜thinches to 2⅛thinches, 1⅜thinches to 2 1/16thinches, 1⅜thinches to 2 inches, 1⅜thinches to 1 15/16thinches, 1⅜thinches to 1⅞thinches, 1⅜thinches to 1 13/16thinches, 1⅜thinches to 1¾thinches, 1⅜thinches to 1 11/16thinches, 1⅜thinches to 1⅝thinches, 1⅜thinches to 1 9/16thinches, 1⅜thinches to 1½ inches, 1⅜thinches to 1 7/16thinches, 1 7/16thinches to 3 inches, 1 7/16thinches to 2 15/16thinches, 1 7/16thinches to 2⅞thinches, 1 7/16thinches to 2 13/16thinches, 1 7/16thinches to 2¾thinches, 1 7/16thinches to 2 11/16thinches, 1 7/16thinches to 2⅝thinches, 1 7/16thinches to 2 9/16thinches, 1 7/16thinches to 2½ inches, 1 7/16thinches to 2 7/16thinches, 1 7/16thinches to 2⅜thinches, 1 7/16thinches to 2 5/16thinches, 1 7/16thinches to 2¼thinches, 1 7/16thinches to 2⅛thinches, 1 7/16thinches to 2 1/16thinches, 1 7/16thinches to 2 inches, 1 7/16thinches to 1 15/16thinches, 1 7/16thinches to 1⅞thinches, 1 7/16thinches to 1 13/16thinches, 1 7/16thinches to 1¾thinches, 1 7/16thinches to 1 11/16thinches, 1 7/16thinches to 1⅝thinches, 1 7/16thinches to 1 9/16thinches, 1 7/16thinches to 1½ inches, 1½ inches to 3 inches, 1½ inches to 2 15/16thinches, 1½ inches to 2⅞thinches, 1½ inches to 2 13/16thinches, 1½ inches to 2¾thinches, 1½ inches to 2 11/16thinches, 1½ inches to 2⅝thinches, 1½ inches to 2 9/16thinches, 1½ inches to 2½ inches, 1½ inches to 2 7/16thinches, 1½ inches to 2⅜thinches, 1½ inches to 2 5/16thinches, 1½ inches to 2¼thinches, 1½ inches to 2⅛thinches, 1½ inches to 2 1/16thinches, 1½ inches to 2 inches, 1½ inches to 1 15/16thinches, 1½ inches to 1⅞thinches, 1½ inches to 1 13/16thinches, 1½ inches to 1¾thinches, 1½ inches to 1 11/16thinches, 1½ inches to 1⅝thinches, 1½ inches to 1 9/16thinches, 1 9/16thinches to 3 inches, 1 9/16thinches to 2 15/16thinches, 1 9/16thinches to 2⅞thinches, 1 9/16thinches to 2 13/16thinches, 1 9/16thinches to 2¾thinches, 1 9/16thinches to 2 11/16thinches, 1 9/16thinches to 2⅝thinches, 1 9/16thinches to 2 9/16thinches, 1 9/16thinches to 2½ inches, 1 9/16thinches to 2 7/16thinches, 1 9/16thinches to 2⅜thinches, 1 9/16thinches to 2 5/16thinches, 1 9/16thinches to 2¼thinches, 1 9/16thinches to 2⅛thinches, 1 9/16thinches to 2 1/16thinches, 1 9/16thinches to 2 inches, 1/ 9/16thinches to 1 15/16thinches, 1 9/16thinches to 1⅞thinches, 1 9/16thinches to 1 13/16thinches, 1 9/16thinches to 1¾thinches, 1 9/16thinches to 1 11/16thinches, 1⅝thinches to 3 inches, 1⅝thinches to 2 15/16thinches, 1⅝thinches to 2⅞thinches, 1⅝thinches to 2 13/16thinches, 1⅝thinches to 2¾thinches, 1⅝thinches to 2 11/16thinches, 1⅝thinches to 2⅝thinches, 1⅝thinches to 2 9/16thinches, 1⅝thinches to 2½ inches, 1⅝thinches to 2 7/16thinches, 1⅝thinches to 2⅜thinches, 1⅝thinches to 2 5/16thinches, 1⅝thinches to 2¼thinches, 1⅝thinches to 2⅛thinches, 1⅝thinches to 2 1/16thinches, 1⅝thinches to 2 inches, 1⅝thinches to 1 15/16thinches, 1⅝thinches to 1⅞thinches, 1⅝thinches to 1 13/16thinches, 1⅝thinches to 1¾thinches, 1⅝thinches to 1 11/16thinches, 1 11/16thinches to 3 inches, 1 11/16thinches to 2 15/16thinches, 1 11/16thinches to 2⅞thinches, 1 11/16thinches to 2 13/16thinches, 1 11/16thinches to 2¾thinches, 1 11/16thinches to 2 11/16thinches, 1 11/16thinches to 2⅝thinches, 1 11/16thinches to 2 9/16thinches, 1 11/16thinches to 2½ inches, 1 11/16thinches to 2 7/16thinches, 1 11/16thinches to 2⅜thinches, 1 11/16thinches to 2 5/16thinches, 1 11/16thinches to 2¼thinches, 1 11/16thinches to 2⅛thinches, 1 11/16thinches to 2 1/16thinches, 1 11/16thinches to 2 inches, 1 11/16thinches to 1 15/16thinches, 1 11/16thinches to 1⅞thinches, 1 11/16thinches to 1 13/16thinches, 1 11/16thinches to 1¾thinches, 1¾thinches to 3 inches, 1¾thinches to 2 15/16thinches, 1¾thinches to 2⅞thinches, 1¾thinches to 2 13/16thinches, 1¾thinches to 2¾thinches, 1¾thinches to 2 11/16thinches, 1¾thinches to 2⅝thinches, 1¾thinches to 2 9/16thinches, 1¾thinches to 2½ inches, 1¾thinches to 2 7/16thinches, 1¾thinches to 2⅜thinches, 1¾thinches to 2 5/16thinches, 1¾thinches to 2¼thinches, 1¾thinches to 2⅛thinches, 1¾thinches to 2 1/16thinches, 1¾thinches to 2 inches, 1¾thinches to 1 15/16thinches, 1¾thinches to 1⅞thinches, 1¾thinches to 1 13/16thinches, 1 13/16thinches to 3 inches, 1 13/16thinches to 2 15/16thinches, 1 13/16thinches to 2⅞thinches, 1 13/16thinches to 2 13/16thinches, 1 13/16thinches to 2¾thinches, 1 13/16thinches to 2 11/16thinches, 1 13/16thinches to 2⅝thinches, 1 13/16thinches to 2 9/16thinches, 1 13/16thinches to 2½ inches, 1 13/16thinches to 2 7/16thinches, 1 13/16thinches to 2⅜thinches, 1 13/16thinches to 2 5/16thinches, 1 13/16thinches to 2¼thinches, 1 13/16thinches to 2⅛thinches, 1 13/16thinches to 2 1/16thinches, 1 13/16thinches to 2 inches, 1 13/16thinches to 1 15/16thinches, 1 13/16thinches to 1⅞thinches, 1⅞thinches to 3 inches, 1⅞thinches to 2 15/16thinches, 1⅞thinches to 2⅞thinches, 1⅞thinches to 2 13/16thinches, 1⅞thinches to 2¾thinches, 1⅞thinches to 2 11/16thinches, 1⅞thinches to 2⅝thinches, 1⅞thinches to 2 9/16thinches, 1⅞thinches to 2½ inches, 1⅞thinches to 2 7/16thinches, 1⅞thinches to 2⅜thinches, 1⅞thinches to 2 5/16thinches, 1⅞thinches to 2¼thinches, 1⅞thinches to 2⅛thinches, 1⅞thinches to 2 1/16thinches, 1⅞thinches to 2 inches, 1⅞thinches to 1 15/16thinches, 1 15/16thinches to 3 inches, 1 15/16thinches to 2 15/16thinches, 1 15/16thinches to 2⅞thinches, 1 15/16thinches to 2 13/16thinches, 1 15/16thinches to 2¾thinches, 1 15/16thinches to 2 11/16thinches, 1 15/16thinches to 2⅝thinches, 1 15/16thinches to 2 9/16thinches, 1 15/16thinches to 2½ inches, 1 15/16thinches to 2 7/16thinches, 1 15/16thinches to 2⅜thinches, 1 15/16thinches to 2 5/16thinches, 1 15/16thinches to 2¼thinches, 1 15/16thinches to 2⅛thinches, 1 15/16thinches to 2 1/16thinches, 1 15/16thinches to 2 inches, 2 inches to 3 inches, 2 inches to 2 15/16thinches, 2 inches to 2 13/16thinches, 2 inches to 2¾thinches, 2 inches to 2 11/16thinches, 2 inches to 2⅝thinches, 2 inches to 2 9/16thinches, 2 inches to 2½ inches, 2 inches to 2 7/16thinches, 2 inches to 2⅜thinches, 2 inches to 2 5/16thinches, 2 inches to 2¼thinches, 2 inches to 2⅛thinches, 2 inches to 2 1/16thinches, 2 1/16thinches to 3 inches, 2 1/16thinches to 2 15/16thinches, 2 1/16thinches to 2⅞thinches, 2 1/16thinches to 2 13/16thinches, 2 1/16thinches to 2¾thinches, 2 1/16thinches to 2 11/16thinches, 2 1/16thinches to 2⅝thinches, 2 1/16thinches to 2 9/16thinches, 2 1/16thto 2½ inches, 2 1/16thinches to 2 7/16thinches, 2 1/16thinches to 2⅜thinches, 2 1/16thinches to 2 5/16thinches, 2 1/16thinches to 2¼thinches, 2 1/16thinches to 2 3/16thinches, 2 1/16thinches to 2⅛thinches, 2⅛thinches to 3 inches, 2⅛thinches to 2 15/16thinches, 2⅛thinches to 2⅞thinches, 2⅛thinches to 2 13/16thinches, 2⅛thinches to 2¾thinches, 2⅛thinches to 2 11/16thinches, 2⅛thinches to 2⅝thinches, 2⅛thinches to 2 9/16thinches, 2⅛thto 2½ inches, 2⅛thinches to 2 7/16thinches, 2⅛thinches to 2⅜thinches, 2⅛thinches to 2 5/16thinches, 2⅛thinches to 2¼thinches, 2⅛thinches to 2 3/16thinches, 2 3/16thinches to 3 inches, 2 3/16thinches to 2 15/16thinches, 2 3/16thinches to 2⅞thinches, 2 3/16thinches to 2 13/16thinches, 2 3/16thinches to 2¾thinches, 23/16thinches to 2 11/16thinches, 2 3/16thinches to 2⅝thinches, 2 3/16thinches to 2 9/16thinches, 2 3/16thto 2½ inches, 2 3/16thinches to 2 7/16thinches, 2 3/16thinches to 2⅜thinches, 2 3/16thinches to 2 5/16thinches, 2 3/16thinches to 2¼thinches, 2¼thinches to 3 inches, 2¼thinches to 2 15/16thinches, 2¼thinches to 2⅞thinches, 2¼thinches to 2 13/16thinches, 2¼thinches to 2¾thinches, 2¼thinches to 2 11/16thinches, 2¼thinches to 2⅝thinches, 2¼thinches to 2 9/16thinches, 2¼thto 2½ inches, 2¼thinches to 2 7/16thinches, 2¼thinches to 2⅜thinches, 2¼thinches to 2 5/16thinches, 2 5/16thinches to 3 inches, 2 5/16thinches to 2 15/16thinches, 2 5/16thinches to 2⅞thinches, 2 5/16thinches to 2 13/16thinches, 2 5/16thinches to 2¾thinches, 2 5/16thinches to 2 11/16thinches, 2 5/16thinches to 2⅝thinches, 2 5/16thinches to 2 9/16thinches, 2 5/16thinches to 2½ inches, 2 5/16thinches to 2 7/16thinches, 2 5/16thinches to ⅜thinches, 2⅜thinches to 3 inches, 2⅜thinches to 2 15/16thinches, 2⅜thinches to 2⅞thinches, 2⅜thinches to 2 13/16thinches, 2⅜thinches to 2¾thinches, 2⅜thinches to 2 11/16thinches, 2⅜thinches to 2⅝thinches, 2⅜thinches to 2 9/16thinches, 2⅜thinches to 2½ inches, 2⅜thinches to 2 7/16thinches, 2 7/16thinches to 3 inches, 2 7/16thinches to 2 15/16thinches, 2 7/16thinches to 2⅞thinches, 2 7/16thinches to 2 13/16thinches, 2 7/16thinches to 2¾thinches, 2 7/16thinches to 2 11/16thinches, 2 7/16thinches to 2⅝thinches, 2 7/16thinches to 2 9/16thinches, 2 7/16thinches to 2½ inches, 2½ inches to 3 inches, 2½ inches to 2 15/16thinches, 2½ inches to 2⅞thinches, 2½ inches to 2 13/16thinches, 2½ inches to 2¾ inches, 2½ inches to 2 11/16thinches, 2½ inches to 2⅝thinches, 2½ inches to 2 9/16thinches, 2 9/16thinches to 3 inches, 2 9/16thinches to 2 15/16thinches, 2 9/16thinches to 2⅞thinches, 2 9/16thinches to 2 13/16thinches, 2 9/16thinches to 2¾ inches, 2 9/16thinches to 2 11/16thinches, 2 9/16thinches to 2⅝thinches, 2⅝thinches to 3 inches, 2⅝thinches to 2 15/16thinches, 2⅝thinches to 2⅞thinches, 2⅝thinches to 2 13/16thinches, 2⅝thinches to 2¾ inches, 2⅝thinches to 2 11/16thinches, 2 11/16thinches to 3 inches, 2 11/16thinches to 2 15/16thinches, 2 11/16thinches to 2⅞thinches, 2 11/16thinches to 2 13/16thinches, 2 11/16thinches to 2¾ inches, 2¾thinches to 3 inches, 2¾thinches to 2 15/16thinches, 2¾thinches to 2⅞thinches, 2¾thinches to 2 13/16thinches, 2 13/16thinches to 3 inches, 2 13/16thinches to 2 15/16thinches, 2 13/16thinches to 2⅞thinches, 2⅞thinches to 3 inches, 2⅞thinches to 2 15/16thinches, and 2 15/16thinches to 3 inches. Other lengths also can be provided.

In embodiments, the surfacing media46of the sealant attachment zone41can include various particulate materials. For example, in embodiments, sand, granule fines, talcs, stone dust, synthetic particles, polymer particles, composite particles, rubber particles, waxes, or any suitable particles or other suitable materials or combinations thereof. As shown inFIGS.1and3B, in some embodiments, the sealant attachment zone41can include a surfacing media that comprises a different material than the headlap and butt granules, including different types of granules providing a different appearance from exposure and the headlap portions of the cap shingles (e.g., the color and/or the texture of the surfacing materials can be different).

In addition, in embodiments, the sealant attachment zone41can include materials that have an affinity for the sealant30adapted for enhancing the adhesion between the overlapping cap shingles. For example, the sealant attachment zone41material can include a surfacing media46comprising polar polymers having affinity to asphalt, scrim or tape materials with functionalized surfaces, adhesion promoters, surfaces with tackifiers' surfaces with surface treatments to enhance sealant bonds; polymer films or coatings or other suitable materials; or combinations thereof. In some embodiments, the surfacing materials can include fines and/or other particulate materials such as sand, limestone particles, fillers, varying size granules, which can include, in some embodiments headlap and/or butt granules, or combinations thereof.

In embodiments, the particulate materials can have various sizes; and in some embodiments can have a size of 4 US standard sieve size (4.75 mm) to 325 US standard sieve size (0.044 mm). For example, in embodiments where granules, such as headlap granules, butt granules, other types of granules, or combinations thereof, are used, such granules can have a size of 10 US standard sieve size (1.70 mm) to 50 US standard sieve size (0.30 mm), and in some embodiments, can have a size of 10 US standard sieve size (1.70 mm) to 40 US standard sieve size (0.42 mm); 10 US standard sieve size (1.70 mm) to 30 US standard sieve size (0.59 mm); 10 US standard sieve size (1.70 mm) to 20 US standard sieve size (0.84 mm); 20 US standard sieve size (0.84 mm) to 50 US standard sieve size (0.30 mm); 20 US standard sieve size (0.84 mm) to 40 US standard sieve size (0.42 mm); 20 US standard sieve size (0.84 mm) to 30 US standard sieve size (0.59 mm); 30 US standard sieve size (0.59 mm) to 50 US standard sieve size (0.30 mm); or 30 US standard sieve size (0.59 mm) to 40 US standard sieve size (0.42 mm). In other embodiments, other varying size and types of granules also can be used.

In embodiments, such as where the surfacing media comprises other particulates such as sand, such particulates of the surfacing media can have a size of 30 US standard sieve size (0.59 mm) to 100 US standard sieve size (0.149 mm); and in some embodiments, can have a size of 30 US standard sieve size (0.59 mm) to 80 US standard sieve size (0.177 mm); 30 US standard sieve size (0.59 mm) to 70 US standard sieve size (0.21 mm); 30 US standard sieve size (0.59 mm) to 60 US standard sieve size (0.25 mm); 30 US standard sieve size (0.59 mm) to 50 US standard sieve size (0.30 mm); 30 US standard sieve size (0.59 mm) to 40 US standard sieve size (0.42 mm); 40 US standard sieve size (0.42 mm) to 100 US standard sieve size (0.149 mm); 40 US standard sieve size (0.42 mm) to 80 US standard sieve size (0.177 mm); 40 US standard sieve size (0.42 mm) to 70 US standard sieve size (0.21 mm); 40 US standard sieve size (0.59 mm) to 60 US standard sieve size (0.25 mm); 40 US standard sieve size (0.59 mm) to 50 US standard sieve size (0.30 mm); 50 US standard sieve size (0.30 mm) to 100 US standard sieve size (0.149 mm); 50 US standard sieve size (0.30 mm) to 80 US standard sieve size (0.177 mm); 50 US standard sieve size (0.30 mm) to 70 US standard sieve size (0.21 mm); 50 US standard sieve size (0.30 mm) to 60 US standard sieve size (0.25 mm); 60 US standard sieve size (0.25 mm) to 100 US standard sieve size (0.149 mm); 60 US standard sieve size (0.25 mm) to 80 US standard sieve size (0.177 mm); 60 US standard sieve size (0.25 mm) to 70 US standard sieve size (0.21 mm); 70 US standard sieve size (0.21 mm) to 100 US standard sieve size (0.149 mm); 70 US standard sieve size (0.21 mm) to 80 US standard sieve size (0.177 mm); and 80 US standard sieve size (0.177 mm) to 100 US standard sieve size (0.149 mm). Other size sand particles also can be used.

In some embodiments, smaller particulate materials also can be used as the surfacing media or at least a portion thereof. For example, limestone particles or filler materials can be used, having a size of 100 US standard sieve size (0.149 mm) to 325 US standard sieve size (0.044 mm); and in some embodiments, such particulate materials can have a size of 100 US standard sieve size (0.149 mm) to 270 US standard sieve size (0.053 mm); 100 US standard sieve size (0.149 mm) to 230 US standard sieve size (0.062 mm); 100 US standard sieve size (0.149 mm) to 200 US standard sieve size (0.074 mm); 100 US standard sieve size (0.149 mm) to 170 US standard sieve size (0.088 mm); 100 US standard sieve size (0.149 mm) to 140 US standard sieve size (0.105 mm); 100 US standard sieve size (0.149 mm) to 120 US standard sieve size (0.125 mm); 120 US standard sieve size (0.125 mm) to 325 US standard sieve size (0.044 mm); 120 US standard sieve size (0.125 mm) to 270 US standard sieve size (0.053 mm); 120 US standard sieve size (0.125 mm) to 230 US standard sieve size (0.062 mm); 120 US standard sieve size (0.125 mm) to 200 US standard sieve size (0.074 mm); 120 US standard sieve size (0.125 mm) to 170 US standard sieve size (0.088 mm); 120 US standard sieve size (0.125 mm) to 140 US standard sieve size (0.105 mm); 140 US standard sieve size (0.105 mm) to 325 US standard sieve size (0.044 mm); 140 US standard sieve size (0.105 mm) to 270 US standard sieve size (0.053 mm); 140 US standard sieve size (0.105 mm) to 230 US standard sieve size (0.062 mm); 140 US standard sieve size (0.105 mm) to 200 US standard sieve size (0.074 mm); 140 US standard sieve size (0.105 mm) to 170 US standard sieve size (0.088 mm); 170 US standard sieve size (0.088 mm) to 325 US standard sieve size (0.044 mm); 170 US standard sieve size (0.088 mm) to 270 US standard sieve size (0.053 mm); 170 US standard sieve size (0.088 mm) to 230 US standard sieve size (0.062 mm); 170 US standard sieve size (0.088 mm) to 200 US standard sieve size (0.074 mm); 200 US standard sieve size (0.074 mm) to 325 US standard sieve size (0.044 mm); 200 US standard sieve size (0.074 mm) to 270 US standard sieve size (0.053 mm); 200 US standard sieve size (0.074 mm) to 230 US standard sieve size (0.062 mm); 230 US standard sieve size (0.062 mm) to 325 US standard sieve size (0.044 mm); 230 US standard sieve size (0.062 mm) to 270 US standard sieve size (0.053 mm); and 270 US standard sieve size (0.053 mm) to 325 US standard sieve size (0.044 mm).

In embodiments, the sealant attachment zone can be configured to provide aesthetic features or effects, such as shading, creation of shadow lines61(FIGS.6B-6C), an appearance of increased thickness, and other features and/or combinations thereof. In some embodiments, the visible distinctiveness of the sealant attachment zone41(FIG.1A) relative to the remainder of the headlap13and the exposure portion12also can be configured to provide a visually distinct alignment guide50for assisting installers in aligning the cap shingles10with previously installed cap shingles during installation on a roof. For example, the sealant attachment zone41, or at least a portion thereof, can function as an alignment guide50of the front edge of the exposure portion of a next cap shingle10that can guide a roofer in properly aligning and positioning the cap shingle10so as to cover the headlap portion of a previously installed cap shingle without extending over the exposure portion thereof during installation of the cap shingles on a roof.

In exemplary embodiments, the visual distinctiveness of the sealant attachment zone41can be a result of the remainder of the headlap13, outside of the sealant attachment zone41, including larger particles (e.g., headlap granules) and the sealant attachment zone41including fines or particles of a smaller size than the headlap and butt granules, and a reduced amount of granules or no granules (e.g., including an area of no granules, dust, fines, or combinations thereof), or differences in the surfacing media applied to the sealant attachment zone versus the headlap granules (e.g., the type color, amounts, etc. . . . ). In some embodiments, the surfacing materials also can be applied in varying thicknesses or can be otherwise configured to create shading or an appearance of a transition between the headlap portion13and the exposure portion12, such as creating shadow lines61as indicated inFIGS.6B-6C.

In addition, or alternatively, the surfacing media applied along the sealant attachment zone41can be configured to define an alignment guide50provided by the sealant attachment zone for use by installers to align the front edge20of each cap shingle with the rear edge of the exposure portion of a previously installed cap shingle. In an embodiment, the surfacing media can have a different color or shade than the materials of the remainder of the headlap portion13and/or the exposure portion12.

In other embodiments, the alignment guide50can comprise at least one marking line such as a paint line or particles with a different and contrasting color, which can be included along a portion of the sealant attachment zone41, such as along the front edge43of the sealant attachment zone41proximate to the exposure portion12of the cap shingle10, or can be applied along the rear edge12A of the exposure portion12to enhance the visibility of the point of transition between the headlap and exposure areas for alignment of the cap shingles during installation. In embodiments, one or more marking lines can be located between the headlap granules of the remainder of the headlap portion13and the butt granules of the exposure portion12. In embodiments, the one or more marking lines can have a different or contrasting color or shade than the headlap granules and the butt granules.

In embodiments, materials with high visibility can be used to form the sealant attachment zone41, such that the sealant attachment zone, and in embodiments, the front edge thereof, are highly visible to an installer for guiding the installer to properly align the cap shingles10with one another between courses when installing the cap shingles10along a ridge, hip, or cap of a roof. According to exemplary embodiments, the visually distinctive materials of the sealant attachment zone41(e.g., marking lines, different color surfacing media, and/or other indicators) can provide an alignment guide that is more easily seen and/or that is less likely to smear or be removed than a paint line alone.

An example of the alignment and bonding of two cap shingles10(e.g., in a first course and a second course) is schematically shown inFIGS.2and3A-4B. In the illustrated embodiments, one of the cap shingles10is installed along the ridge, hip, or cap of a roof in a first course. Subsequently, a next cap shingle10can be aligned with the installed cap shingle10. For example, the front edge43of the sealant attachment zone41can be located along each cap shingle10between the headlap and exposure portions of the cap shingles, and can define a transition area60therebetween, so that the exposure portion of each subsequently installed cap shingle10is properly aligned with and overlaps the headlap portion13of the previously installed cap shingle10(e.g., being aligned with the front edge43of the sealant attachment zone41FIG.4A).

When the cap shingles10are aligned in this way, the sealant30of the subsequently installed cap shingle10can extend along and contact the sealant attachment zone41of the previously installed cap shingle10. Accordingly, each cap shingle10can be installed onto a previously installed cap shingle10(e.g. in an overlapping arrangement) so that the sealant30of the next cap shingle to be installed and the sealant attachment zone41of the previously installed cap shingle are properly aligned and will be placed into contact so as to provide improved, more direct contact therebetween thus providing enhanced bonding between the sealant30and the asphalt material of the cap shingles10.

For purposes of illustration and not limitation,FIGS.1A-1B and5A-5Cillustrate example embodiments of a single cap shingle10. It will also be, and in some embodiments more than one layer of shingle material, understood that the cap shingles10can be formed from a web of shingle material and cut into sheets that can include multiple cap shingles10. In embodiment, the sheets can also include perforation or tear lines separating the individual cap shingles. Multiple cap shingles can be provided in separable sheets for ease of transport.

In embodiments, as indicated inFIGS.5A-5B, the cap shingles10can include one or more layers11and14. In some embodiments, the layers11,14of one or more cap shingles10can be formed side-by-side along a web of shingle material and can be cut into sheets51of shingle material, and from which one or more cap shingles can be formed. For example, in embodiments as shown inFIGS.5A and5B, two top layers11(e.g., for two different cap shingles10) can be located along a central portion of the sheet51and can be separable from one another along a cut or tear line53. The sheet51also can include two bottom layers14(e.g., corresponding to the cap shingles10associated with the two top layers11) disposed at the outer portions of the sheet51and separable from the respective inner layers11along cut or tear lines55.FIG.5Ashows a view of a first surface51A of the sheet51corresponding to the uppermost surfaces of the layers11,14, andFIG.5Bshows a view of an opposing second surface51B of the sheet51corresponding to the lowermost surfaces of the layers11,14. In addition, in the embodiment shown inFIGS.5A-5B, a release tape31can be applied along the second surface51B adjacent the rear edge22of the resultant cap shingle.

As shown inFIG.5A, in embodiments, each of the top layers11can be formed with an exposure portion12and a headlap portion13, wherein the sealant attachment zone41is formed in the headlap portion13. In some embodiments, the sealant attachment zone can be formed as part of the exposure portion12, e.g., defining a rear or trailing section thereof, or can be formed as an intermediate area between the headlap and exposure portions.FIG.5Cshows a detailed view of a portion of one of the top layers11, such as shown in the embodiment ofFIG.5A, showing the location of the sealant attachment zone41(FIG.5C) along the headlap portion13relative to the exposure portion12of the cap shingle (e.g., with the front edge43of the sealant attachment zone41spaced a short distance from the rear edge of the exposure portion12). The features of the layers11,14and/or the sheet51can have any suitable dimensions without departing from the scope of the disclosure.

In exemplary embodiments, two cap shingles10can be formed from the layers11,14of the sheet of shingle material51by separating the two bottom layers14from the respective top layers11along the cut or tear lines55, and the two top layers11can be separated from one another along the cut or tear line53. The separated layers11,14can be overlapped and bonded together with the lowermost faces of the top layers11(the faces visible inFIG.5B) contacting the uppermost faces of the respective bottom layers14(the faces visible inFIG.5A). The cap shingles10could be otherwise formed without departing from the disclosure.

In embodiments, the sealant attachment zone41will be configured to help enhance bonding between the cap shingles10, which can help improve the resistance of the shingles to wind and/or other weather elements when installed as part of a roofing system (e.g., schematically shown inFIG.2). For example, in embodiments, the cap shingles will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to and including 90 mph [145 km/h] (Class D in ASTM D7158), in some embodiments, the cap shingles will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to and including 155 mph [249 km/h] (Class G in ASTM D7158); and in other embodiments, the cap shingles will be configured with increased wind resistance sufficient to withstand wind uplift forces from high wind speeds of up to and including 194 mph [312 km/h] (Class H in ASTM D7158) in accordance with ASTM D3161 and/or D7158. The sealant attachment zone41also can function as an installation guide as described above.

In addition, the cap shingles according to embodiments of the present disclosure will be configured to exhibit increased mechanical uplift resistance as measured in accordance with the ASTM D6381 Standard test method for measurement of asphalt shingle tab mechanical uplift resistance. In example testing, cap shingles constructed according to the principles of the present disclosure were tested against two different conventional cap shingles, and as shown in the table below, exhibited a consistently higher maximum load resistance:

ASTM D 6381 Standard test method for measurementof asphalt shingle tab mechanical uplift resistanceMaximum Load [Ibf]ConventionalCap Shingle of theConventionalShingle 1Present DisclosureShingle 221.7331.3812.94915.6329.7116.87816.6626.4118.46629.3130.4522.3528.0227.5213.81420.5237.2712.6110.5329.8621.47513.0128.1114.18912.5729.4120.1820.09—18.52414.18——18.85——Mean16.7630.0117.14Standard5.773.123.60deviation

During testing, samples of each of the Conventional Shingles1and2were compared to a sample cap shingle constructed according to embodiments of the present disclosure. A series of each of the different sample shingles were mounted along a simulated roof ridge or cap, and were subjected to mechanical edge-lift loading. As can be seen, the cap shingles constructed according to the principles of the present disclosure were found to have a mean maximum load mechanical upload resistance of 30.01 lbf.

Further, in some embodiments, the use of fewer or minimized amounts of particulate materials, smaller particles, and, in some embodiments, no particulate materials, in the sealant attachment zone41than are used in the remainder of the headlap13outside the sealant attachment zone41can result in a savings in costs and/or a reduction in the weight of the cap shingles10when compared to cap shingles that do not include a sealant attachment zone formed in the headlap. For example, the use of the sealant attachment zone41can save cost in raw materials and the lower weight of the cap shingles with the sealant attachment zones41can reduce freight costs. Additionally, the lighter weight of the cap shingles10with the sealant attachment zones41can be easier to handle and install.

In embodiments, the sealant material30of the strips33of self-sealing material, and any additional sealant materials applied to the cap shingles, can comprise a self-sealing adhesive including asphalt, filled asphalt, polymer modified asphalts; bitumen, PSA, acrylic adhesives, butyl adhesives or combinations thereof. In embodiments, the sealant material30comprises a self-sealing adhesive including an additive including tackifiers, stabilizers, calcium carbonates, limestone fillers, graphite's, intumescent additives, viscosity modified, oils, adhesion promoters, or combinations thereof. In one embodiment, the sealant material30has a tackiness at temperatures above 70° F. In one embodiment, the sealant material30has a tackiness at temperatures above 65° F. In one embodiment, the sealant material30has a tackiness at temperatures above 60° F. In one embodiment, the sealant material30has a tackiness at temperatures above 55° F. In one embodiment, the sealant material30has a tackiness at temperatures above 50° F. In one embodiment, the sealant material30has a tackiness at temperatures above 45° F. In one embodiment, for example, such as for cold weather installations, the sealant material30has a tackiness at temperatures above 40° F. Other sealant materials with a tackiness less than 40° F. also can be used.

In addition, in some embodiments, a combination of sealant materials can be used, including two or more sealant materials having different properties. For example, in embodiments, a first sealant material having a tackiness at a lower temperature (e.g., 40° F. or less) can be used in combination with a sealant material having a tackiness at a higher temperature (e.g., greater than 40° F.), with the lower temperature sealant material providing for a faster initial adhesion between the sealant of a next cap shingle and the asphaltic coating along the sealant attachment zone of a previously installed cap shingle when installed in cold weather conditions (e.g., 50° F. or lower), and with this adhesive bond increasing due to the higher temperature sealant material as the cap shingles are exposed to heat from sunlight and/or to increased temperatures.

In embodiments, the asphaltic coatings applied to the top and/or bottom surfaces of the shingle material can include filled asphalts, polymer modified asphalts; bitumen, PSA, acrylic adhesives, butyl adhesives or combinations thereof.

According to embodiments of the present disclosure, a method for forming the cap shingles10is provided. In an embodiment, a ribbon or web of shingle material, having first and second surfaces, is moved along a processing path. In embodiments, the web of shingle material can include a woven, non-woven, or laminated fabric (e.g., a multi-layer fabric), a mat, scrim, sheet, fibrous web, or a ribbon of shingle material, or combinations thereof. In embodiments, a coating can be applied to the ribbon or web of shingle material. In embodiments, the coating can include an asphaltic coating applied to its upper and/or lower faces, and in some embodiments, the ribbon or web of shingle material saturated with an asphalt material. In addition, the web of shingle material can comprise a single fabric web or layer of shingle material, or multiple layers of shingle materials.

In embodiments, as the web of shingle material is moved along the processing path, a plurality of granules can be applied along a surface of the shingle material. For example, a first plurality of granules (e.g., headlap granules) can be applied along the surface of the shingle material (e.g., in embodiments, the first surface) that will form the headlap portions and a second plurality of granules (e.g., butt granules) can be applied along the surface of the shingle material along portions of the shingle material that will form the exposure portions of the cap shingles.

Sealant attachment zones can be formed between respective applications of the headlap granules and butt granules to the web of shingle material. In embodiments, the sealant attachment zones can include areas where the asphaltic coating of the web of shingle material left substantially exposed, e.g., where a surfacing media is not applied. In some embodiments, the sealant attachment zones can further include an application of a surfacing media, that can be applied separately from the headlap and butt granules, adapted to promote enhanced adhesion between the asphaltic coating of the first or upper surface of a first cap shingle and a strip of a sealant material of a second cap shingle when the first and second cap shingles are arranged in a stack of cap shingles.

In embodiments, a system for forming the cap shingles can include a tape applicator, a sealant material applicator, such as an applicator wheel, extruder, sprayer, or other devices, and cutters for cutting the web of shingle material to form a plurality of cap shingles. As the web of a shingle material is moved along the processing path, strips of a self-sealing sealant material can be applied to the second surface thereof, e.g., in a pattern such as one or more dots, dashes, lines, or combinations thereof; and surfacing materials can be applied to the sealant attachment zone for example, in embodiments, the web of shingle material can move past one or more applicators that can apply the sealant material, and, in some embodiments, apply the surfacing media.

In embodiments, the web of shingle material can be engaged by a tape applicator that can apply a length of the release tape to the web of shingle material as the web of shingle material is moved in the machine direction. In embodiments, the sealant material applicator can apply strips of a self-sealing sealant material to the lower surfaces of the web of shingle material.

In embodiments, the web of shingle material can move along a path through various stations and past various applicators for applying granules, sealant, a surfacing media, etc. For example, the web of shingle material can move into engagement with a sealant material applicator that, in embodiments, can include one or more spray nozzles, an extruder, or a rotary applicator, which moves, e.g., rotates, in sync with the movement of the web of shingle material to apply the sealant material thereto, which can be formed as one or more strips of a self-sealing material along portions of the web of shingle material. In embodiments, chop cutters can be used to repeatedly cut the web of shingle material for forming the cap shingles10. In embodiments, the system can be configured to form shingle material sheets51(FIGS.5A-5B), which can be cut into layers11,14and formed into cap shingles10as described above.

In embodiments, the exposure portions12of the cap shingles10can have one or more aesthetic features added. For example, in embodiments, as shown inFIGS.6A-6C, one or more lines (e.g., shadow lines61) can be added to the exposure portions and/or to the sealant attachment zone. For example, in embodiments, markings or other aesthetic features can be provides along the rear edge12A or at a transition point between the exposure portion12and the sealant attachment zone12, such as by painting and/or by using different colored surfacing materials. As shown inFIG.6B, in some embodiments, a shadow line61is included at the rear portions of the exposure portions12that provides an illusion of increased depth as compared to the exposure portions12without shadow lines shown inFIG.6A. In another embodiment, two shadow lines61can be applied to each edge of the exposure portion12of a cap shingle as shown inFIG.6C, one adjacent each of the front and rear edges of the exposure portion12for a further enhanced depth effect.

In another, alternative embodiment, the sealant attachment zone41(FIG.1A) can include a strip of sealant applied along at least a portion thereof. For example, in embodiments, a ribbon or web of shingle material can be fed along a processing path, and a plurality of granules, which can include headlap and butt granules, or combinations thereof, can be applied to selected areas or regions of a surface thereof. In embodiments, a sealant attachment zone also can be defined along the surface of the moving web of shingle material between the applications of the headlap and butt granules.

Thereafter, in embodiments, a strip of sealant material could be applied to the moving ribbon or web of shingle material, with the strip of sealant material having a width and length sufficient to substantially cover a selected area of the upper surface of a cap shingle formed from the ribbon or web of shingle material, adjacent the transition point between the headlap and exposure portions of the cap shingle (for example, adjacent a leading edge of the sealant attachment zone or along the rear edge12A of the exposure portion12of the cap shingle, such as indicted inFIG.1A). In some embodiments, the strip of sealant material can be applied so as to cover a selected portion of the sealant attachment zone, e.g., less than the full area of the sealant attachment zone; and in some embodiments can be applied with a width and length sufficient to substantially cover the sealant attachment zone.

In embodiments, the ribbon or web of shingle material can continue along its path of travel past one or more cutters that will cut the ribbon or web of shingle materials to form cap shingles. In embodiments, single cap shingles can be formed from the ribbon or web of shingle material. In some embodiments, sheets of multiple cap shingles can be formed, with individual cap shingles being separable from the sheet.

In some embodiments of a method of forming a cap shingle10, the sealant attachment zone41can be formed along a surface of an asphalt coated web of shingle material between the headlap granules and the butt granules applied to the surface of the web of shingle material. In some embodiments, the sealant attachment zone can have a surfacing media applied therealong, which surfacing media will be configured to promote enhanced adhesion between an exposed portion of the asphalt coated surface of the web of shingle material defined by the sealant attachment zone, while also providing protection to the exposed portion of the asphalt coated surface.

In other embodiments, the sealant attachment zone may not have a surfacing media applied thereto and can comprise an area where the portion of the asphalt coated surface of the web of shingle material along which the sealant attachment zone is defined remains substantially exposed to the surrounding environment.

In embodiments, a strip of a sealant material can be applied along the sealant attachment zone, located above the exposure portion of each resultant cap shingle, and positioned between the applied headlap and butt granules. In some embodiments, the strip of sealant material can be applied directly to the asphalt coated surface of the web of shingle material sealant along the sealant attachment zone41, without a surfacing media, such as fines or other particulate matter, tackifiers, or other surfacing media having been applied to the surface of the web of shingle material along the sealant attachment zone. In some embodiments, the strip of sealant material can be applied over a surfacing media that is previously applied to the sealant attachment zone. Thereafter, in embodiments, a releasable covering material, such as a release tape or other, similar material, can be applied over the strip of sealant material.

In embodiments, the web of shingle material will then be cut into cap shingles, e.g., being cut into individual cap shingles, or into sheets of two or more cap shingles that can be separated into individual cap shingles along tear lines; and stacked and packaged to form cap shingle packages. By arranging the strip of sealant material along the sealant attachment zone defined along the first or upper side of the cap shingles, packaging of the cap shingles may be made simpler and more efficient as the cap shingles may not have to be stacked in pairs with every other cap shingle flipped.

The present disclosure has been described herein in terms of examples that illustrate principles and aspects of the present disclosure. The skilled artisan will understand, however, that a wide gamut of additions, deletions, and modifications, both subtle and gross, may be made to the presented examples without departing from the spirit and scope of the present disclosure.