High profile composition shingles for roofs

Abstract

A high profile shingle for roofs includes a weather layer of composition material and a plurality of members of composition material arranged under said weather layer which are of varying lengths and arranged to cause the butt end of the shingle to be substantially thicker than the weather layer. In one embodiment, the members under the weather layer are a series of spaced, tapered strips arranged with their thick ends toward one end of the shingle and having an additional end strip abutted against the thick ends. Another embodiment uses a series of underlayers of the same width as the weather layer but of lengths varying from approximately one-half down to about one-eighth the length of the weather layer. A third embodiment uses a base layer of substantially greater width than the weather layer, a series of layers of progressively shorter lengths below the weather layer with the ends of the layers in registry at the butt end of the shingle with cut-out sections. A fourth embodiment comprises a weather layer and a plurality of underlayers of different lengths and the same width as the weather layer. The underlayers have one end aligned, their surfaces all bonded to its adjacent layer and fastened by staples with the outermost longest underlayment layer bonded to the underside of the weather layer. One edge of the weather layer and the common edges of the underlayment layers constituting the butt of the shingle.

Description

REFERENCE TO RELATED APPLICATION [0001] This Non-Provisional Patent Application claims benefit of U.S. Provisional Patent Application Ser. No. 60 / 507,994 filed Oct. 1, 2003, and hereby claims the benefit of the embodiments therein and of the filing date thereof.BACKGROUND OF THE INVENTION [0002] The need for improved roofing materials as substitutes for actual slate or wooden shake shingles has been recognized for many years. The classic slate roofs commonly used abroad, and in some of the most expensive homes in the United States of America, are characterized by their expense and, most importantly, in the extreme weight of slate shingles which typically run to over 1000 pounds per square. [0003] Wood shake shingles are quite attractive due to their irregularity and their depth presenting a high profile; however, they are significantly more expensive than composition shingles and do not meet the fire safety codes. Attempts have been made to fireproof them with varying degrees of suc...

AI Technical Summary

Benefits of technology

[0011] It is possible to make such shingles solely from composition materials with multiple layers, adding greatly to the depth of the body and of the shingles, and providing a tapered appearance on the sides of the shingles, while maintaining a weight that is within the range of composition roofs and not exceeding the weight of other simulated slate or shake shingles. This roof meets all the fire code standards or exceeds the standards of a conventional composition roof.

[0013] In another and preferred embodiment, the shingle is formed of a weather layer backed by a series of graduated length, full width single layers. Each are adhered to adjacent layers by suitable roofing adhesive. The butt end has the greatest number of layers, e.g., six, including the weather layer. The underlayers may be granule covered or not. Granules can add depth and provide good bonding. Most important is by fastening means, for example, two large roofing staples which penetrate all underlayers and are crimped at their ends, partially embedded in the outer layers. This avoids any visible bumps on the weather layer.

Problems solved by technology

The classic slate roofs commonly used abroad, and in some of the most expensive homes in the United States of America, are characterized by their expense and, most importantly, in the extreme weight of slate shingles which typically run to over 1000 pounds per square.

Wood shake shingles are quite attractive due to their irregularity and their depth presenting a high profile; however, they are significantly more expensive than composition shingles and do not meet the fire safety codes.

Attempts have been made to fireproof them with varying degrees of success, but they still do not meet the fire codes that are easily met by granular covered asphaltic composition roofs.

These materials, while not as heavy as slate, still have weight in the order of 600 pounds per square, and usually lack the irregularity and high profile of natural slate or wood shake.

These materials can be molded to provide the additional thickness found in shake shingles; however, they fail to meet the same fire safety standards as composition roofs.

Other attempts to make multi-layered added thickness composition roofs have results in delamination due to wind alone or in combination with deterioration of adhesive due to solar heating or alternate freezing and thawing of moisture.

Delamination destroys the illusion of thickness and is difficult, if not impossible, to repair.

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