Starter shingle

Abstract

A roofing shingle exhibits improved wind performance when installed near a bottom of a roof deck, owing to the inclusion of a reinforcing member and / or sealant. The roofing shingle can contribute to improved wind resistance of a roofing system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application No. 63 / 765,012, filed on Feb. 28, 2025, the entire disclosure of which is fully incorporated herein by reference.FIELD

[0002] The inventive concepts generally relate to roofing shingles and, in particular, to starter shingles having improved wind resistance.BACKGROUND

[0003] Asphalt-based roofing materials, such as roofing shingles, are installed on the roofs of buildings to provide protection from the elements, and to give the roof an aesthetically pleasing look. Typically, a roofing shingle is constructed of a substrate such as a glass fiber mat or an organic felt, an asphalt coating on the substrate, and a surface layer of granules embedded in the asphalt coating. The shingle constructions may include one or more layers.

[0004] It is known to install roofing shingles (e.g., laminated asphalt shingles) on a sloped roof deck in horizontal layers referred to as “courses” of shingles. Each subsequent course of shingles partially overlaps with the course immediately below it, thereby forming an overlapping shingled surface that facilitates removal of water from the roof. Installation of the shingles starts at the bottom (eave region) of the roof and extends upwards (one course at a time) until reaching or approaching the top (ridge region) of the roof, as shown in FIG. 1A. This installation direction is represented by the dashed line Id in FIG. 1A. A portion of a course that extends past the rake of the roof can simply be cut off.

[0005] The roof deck may include additional structure / materials (e.g., underlayment(s)) applied thereto prior to installation of the shingles, as shown in Detail A of FIG. 1B. For example, the roof deck will typically include a drip edge, which is an L-shaped metal flashing that is installed along the eaves and rakes to direct water away from the fascia to prevent wood rot, deck damage, and pest intrusion. In some cases the drip edge is installed under the underlayment, while in other cases the drip edge is installed over the underlayment.

[0006] Because the first course of shingles do not have a lower course to overlap, a special type of shingle (called a starter and / or strip shingle) is used. The Starter Strip Plus Shingle made by Owens Corning of Toledo, Ohio is one such product.

[0007] Consequently, the dimensions of the starter shingles (e.g., 7¾″×39⅜″ (197 mm×1,000 mm)) are typically narrower than the laminated shingles (e.g., 13¼″×39⅜″ (337 mm×1,000 mm)) that make up the remaining courses of installed shingles. In general, the entire course of starter shingles are covered by the subsequent course of laminated shingles.

[0008] A conventional starter shingle has a relatively simple construction, a (front and back) plan view of which is shown in FIG. 2. See also U.S. Pat. No. 6,199,338, the entire disclosure of which is incorporated herein by reference.

[0009] In particular, the starter shingle is formed as a single-layer sheet 200, which can be formed of the same materials found in a laminated shingle (e.g., a non-woven fiberglass mat coated / impregnated with asphalt). For production, storage, and / or packaging efficiency, the sheet 200 has a perforated center line 202, which allows the sheet 200 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 200-1 and starter shingle 200-2) prior to installation.

[0010] A front side of the sheet 200 includes a pair of sealant strips 204, each sealant strip 204 adjacent to one of the edges of the sheet 200 and each sealant strip 204 substantially equidistant from the center line 202. In this manner, each of starter shingle 200-1 and 200-2 will have one (1) sealant strip 204 on a front side thereof and proximate to one edge thereof. Although the sealant strips 204 in FIG. 2 are shown as a continuous strip / line, the sealant 204 can be applied in a discontinuous manner across a length of the sheet 200.

[0011] Similarly, a back side of the sheet 200 includes a pair of release tapes 206, each release tape 206 adjacent to one of the edges of the sheet 200 and each release tape 206 substantially equidistant from the center line 202. In this manner, each of starter shingle 200-1 and 200-2 will have one (1) release tape 206 on a back side thereof and proximate to one edge thereof.

[0012] The release tapes 206 on the sheet 200 function to prevent one sheet 200 from sticking to another sheet 200, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 204 of one sheet (front) facing the release tapes 206 of the other sheet (back). To facilitate this functioning, a width of the release tapes 206 can be greater than a width of the sealants 204. Furthermore, each of the sealants 204 and the release tapes 206 are offset from their respective edges of the sheets 200 by a distance that promotes alignment thereof when stacked.

[0013] The starter shingles 200-1, 200-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the sealant strip 204 of each starter shingle closer to the bottom of the roof deck. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed slightly past the sealant strip 204 in each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck. The sealant strip 204 of each starter shingle adheres to an overlapping shingle installed over the starting shingle.

[0014] In assessing the performance of shingles (in particular, to estimate performance of a shingle in an installed state), the ability of the shingle to resist damage from wind, such as that resulting from failure of the sealant, is an important property.

[0015] ASTM D3161 is a standard test method for assessing wind resistance of asphalt shingles. There are three classes of wind performance in this test, Class A / 60 mph, Class B / 90 mph, and Class F / 110 mph. It is more desirable for shingles to achieve the Class F wind rating. The testing requires a deck to be constructed at a 2:12 slope and products installed per the manufacturer's instructions. After conditioning at 140° F. for 16 hours, the test decks are then exposed to the wind velocities for a given class rating, with wind perpendicular to the shingle course installation. The test runs for 2 hours, and if the shingle tabs uplift from the deck or show any signs of permanent damage, they are deemed a failure. If the roofing assembly prevents full tabs from lifting up for the 2-hour duration, it is considered a pass.

[0016] One of the challenges with D3161 wind testing is that it does not include specific provisions for starter / strip shingles, which might be referred to as non-standard or accessory shingles. Due to the location and configuration of these shingle accessory products, there is not any language or guidance on how to specifically conduct D3161 testing. This is a known issue in the industry for wind certification of accessory products. The present invention addresses this issue.SUMMARY

[0017] The general inventive concepts relate to improved starter shingles and other shingle accessory products. The inventive starter shingles have modified designs, such that the inventive starter shingles are more likely to directly pass D3161 wind performance testing standards (particularly Class F / 110 mph), as modified to address shingle accessory products, than conventional starter shingles.

[0018] In one exemplary embodiment (a), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; and wherein the front side of the starter shingle includes a reinforcement member that is parallel to an edge of the starter shingle.

[0019] In some exemplary embodiments (based on (a)), the starter shingle has a single layer of the asphalt-coated substrate.

[0020] In some exemplary embodiments (based on (a)), the substrate is a non-woven fiberglass mat.

[0021] In some exemplary embodiments (based on (a)), the reinforcement member is a polyester tape.

[0022] In some exemplary embodiments (based on (a)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0023] In some exemplary embodiments (based on (a)), a gap between the reinforcement member and the edge of the starter shingle is at least 1 inch wide.

[0024] In some exemplary embodiments (based on (a)), the reinforcement member is continuous and extends a length of the starter shingle.

[0025] In one exemplary embodiment (b), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is in proximity to and parallel to a first edge of the starter shingle; wherein the front side of the starter shingle includes a strip of a sealant material that is situated between the reinforcement member and the first edge and that is parallel to the first edge; and wherein the back side of the starter shingle includes a release tape that is in proximity to and parallel to a second edge of the starter shingle.

[0026] In some exemplary embodiments (based on (b)), the starter shingle has a single layer of the asphalt-coated substrate.

[0027] In some exemplary embodiments (based on (b)), the substrate is a non-woven fiberglass mat.

[0028] In some exemplary embodiments (based on (b)), the reinforcement member is a polyester tape.

[0029] In some exemplary embodiments (based on (b)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0030] In some exemplary embodiments (based on (b)), a gap between the reinforcement member and the first edge of the starter shingle is at least 1 inch wide.

[0031] In some exemplary embodiments (based on (b)), the reinforcement member is continuous and extends a length of the starter shingle.

[0032] In some exemplary embodiments (based on (b)), the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

[0033] In some exemplary embodiments (based on (b)), a gap between the strip of the sealant member and the first edge of the starter shingle is less than 2 inches wide.

[0034] In some exemplary embodiments (based on (b)), the release tape is continuous and extends a length of the starter shingle.

[0035] In some exemplary embodiments (based on (b)), a gap between the release tape and the second edge of the starter shingle is less than 2 inches wide.

[0036] In one exemplary embodiment (c), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is parallel to a first edge of the starter shingle; and wherein the back side of the starter shingle includes a strip of a sealant material that is in proximity to and parallel to a second edge of the starter shingle.

[0037] In some exemplary embodiments (based on (c)), the starter shingle has a single layer of the asphalt-coated substrate.

[0038] In some exemplary embodiments (based on (c)), the substrate is a non-woven fiberglass mat.

[0039] In some exemplary embodiments (based on (c)), the reinforcement member is a polyester tape.

[0040] In some exemplary embodiments (based on (c)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0041] In some exemplary embodiments (based on (c)), a gap between the reinforcement member and the first edge of the starter shingle is at least 1 inch wide.

[0042] In some exemplary embodiments (based on (c)), the reinforcement member is continuous and extends a length of the starter shingle.

[0043] In some exemplary embodiments (based on (c)), the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

[0044] In some exemplary embodiments (based on (c)), a gap between the strip of the sealant member and the second edge of the starter shingle is less than 2 inches wide.

[0045] In one exemplary embodiment (d), a roofing system comprises a plurality of starter shingles (e.g., based on (a), (b), and / or (c)), wherein the starter shingles are installed adjacent to one another along at least one of an eave and a rake of a roof deck; and wherein a plurality of shingles are installed adjacent to one another on the roof deck, said shingles at least partially overlapping the starter shingles.

[0046] In some exemplary embodiments (based on (d)), the shingles can withstand wind speeds greater than or equal to 110 mph for at least 2 hours.

[0047] In some exemplary embodiments (based on (d)), the shingles can withstand wind speeds greater than or equal to 160 mph for at least 35 minutes.

[0048] Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

[0050] FIGS. 1A and 1B illustrate a roof where shingles could be installed. FIG. 1A is a diagram of a sloped roof. FIG. 1B is a detailed view of a portion of the sloped roof of FIG. 1A, where a starter shingle would be installed.

[0051] FIG. 2 illustrates a conventional starter shingle by providing a front plan view and back plan view of the conventional starter shingle.

[0052] FIG. 3 illustrates a starter shingle according to a first exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.

[0053] FIG. 4 illustrates a starter shingle according to a second exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.

[0054] FIG. 5 illustrates a starter shingle according to a third exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.DETAILED DESCRIPTION

[0055] Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

[0056] Because there is concern that the conventional starter shingle (shown in FIG. 2) may not pass the D3161 testing should the standard be modified to specifically provide for testing of shingle accessory products, various modified starter shingle embodiments were developed to have an improved chance of passing the D3161-type testing (i.e., that are expected to have improved wind resistance). Three such exemplary embodiments are shown in FIGS. 3-5, respectively.

[0057] Accordingly, the general inventive concepts encompass improved starter shingle constructions, which are more likely to directly pass D3161 wind performance testing standards (particularly Class F / 110 mph) than conventional starter shingles. Consequently, a shingle manufacturer need not resort to the industry practice of attributing the D3161 wind performance of regular shingles to related shingle accessory products (e.g., starter shingles). Instead, the starter shingles are able to pass such testing on their own.

[0058] In a first embodiment, the starter shingle is formed as a single-layer sheet 300, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 3. For production, storage, and / or packaging efficiency, the sheet 300 has a perforated center line 302, which allows the sheet 300 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 300-1 and starter shingle 300-2) prior to installation.

[0059] A front side of the sheet 300 includes a pair of reinforcement members 308, each reinforcement member 308 adjacent to one of the edges of the sheet 300 and each reinforcement member 308 substantially equidistant from the center line 302. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521, each of which is incorporated herein by reference in its entirety.

[0060] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0061] There are no other structural features (e.g., sealant strips, release tapes) added to either side of the starter shingle in this embodiment. In particular, this embodiment relies on a sealant on an underside of shingles to be installed in the next course of shingles (i.e., overlapping the starting shingles 300-1, 300-2, etc.) to bond those shingles with the starter shingles.

[0062] Because there are no sealant strips on the starter shingles of this embodiment, the starter shingles can be readily stacked on one another.

[0063] The starter shingles 300-1, 300-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the reinforcement members 308 of each starter shingle closer to the bottom of the roof deck. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed within the reinforcement members 308 across a length of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck.

[0064] In a second embodiment, the starter shingle is formed as a single-layer sheet 400, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 4. For production, storage, and / or packaging efficiency, the sheet 400 has a perforated center line 402, which allows the sheet 400 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 400-1 and starter shingle 400-2) prior to installation.

[0065] A front side of the sheet 400 includes a pair of sealant strips 404, each sealant strip 404 adjacent to one of the edges of the sheet 400 and each sealant strip 404 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) sealant strip 404 on a front side thereof and proximate to one edge thereof. Although the sealant strips 404 in FIG. 4 are shown as a continuous strip / line, the sealant 404 can be applied in a discontinuous manner across a length of the sheet 400. Here, the composition and location of the sealant 404 can be the same as with the conventional starter shingles shown in FIG. 2.

[0066] The front side of the sheet 400 also includes a pair of reinforcement members 408, each reinforcement member 408 adjacent to one of the edges of the sheet 400, each reinforcement member 408 further from its respective edge than the aforementioned sealant strip 404, and each reinforcement member 408 substantially equidistant from the center line 402. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0067] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0068] A back side of the sheet 400 includes a pair of release tapes 406, each release tape 406 adjacent to one of the edges of the sheet 400 and each release tape 406 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) release tape 406 on a back side thereof and proximate to one edge thereof.

[0069] The release tapes 406 on the sheet 400 function to prevent one sheet 400 from sticking to another sheet 400, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 404 of one sheet (front) facing the release tapes 406 of the other sheet (back). To facilitate this functioning, a width of the release tapes 406 can be greater than a width of the sealants 404. Furthermore, each of the sealants 404 and the release tapes 406 are offset from their respective edges of the sheets 400 by a distance that promotes alignment thereof when stacked.

[0070] The starter shingles 400-1, 400-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the sealant strip 404 of each starter shingle closer to the bottom of the roof deck than the corresponding reinforcement member 408. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed past the sealant strip 404 in the reinforcement member 408 of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck. Then, the sealant strip 404 would bond with an overlying shingle installed over the starter shingle.

[0071] In a third embodiment, the starter shingle is formed as a single-layer sheet 500, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 5. For production, storage, and / or packaging efficiency, the sheet 500 has a perforated center line 502, which allows the sheet 500 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 500-1 and starter shingle 500-2) prior to installation.

[0072] A front side of the sheet 500 includes a pair of reinforcement members 508, each reinforcement member 508 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0073] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0074] A back side of the sheet 500 includes a pair of sealant strips 504, each sealant strip 504 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. In this manner, each of starter shingle 500-1 and 500-2 will have one (1) sealant strip 504 on a back side thereof and proximate to one edge thereof. Although the sealant strips 504 in FIG. 5 are shown as a continuous strip / line, the sealant 504 can be applied in a discontinuous manner across a length of the sheet 500. Here, the composition of the sealant 504 can be the same as with the conventional starter shingles shown in FIG. 2.

[0075] The back side of the sheet 500 also includes a pair of release tapes 506, each release tape 506 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. In this manner, each of starter shingle 500-1 and 500-2 will have one (1) release tape 506 on a back side thereof and proximate to one edge thereof.

[0076] The release tapes 506 on the sheet 500 function to prevent one sheet 500 from sticking to another sheet 500, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 504 of one sheet (back) facing the release tapes 506 of the other sheet (back, turned 180 degrees). To facilitate this functioning, a width of the release tapes 506 can be greater than a width of the sealants 504. Furthermore, each of the sealants 504 and the release tapes 506 are offset from their respective edges of the sheets 500 by a distance that promotes alignment thereof when stacked.

[0077] The starter shingles 500-1, 500-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1) with the sealant strip 504 of each starter shingle closer to the bottom of the roof deck than the corresponding reinforcement member 508. In particular, the sealant 504 is adhered to the roof deck (including any intervening structure, such as an underlayment) and then a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed in the reinforcement member 508 of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to further secure the starter shingle to the roof deck.

[0078] As shown in Table 1, each starter shingle of Embodiment 1, Embodiment 2, and Embodiment 3 were shown to exhibit improved wind resistance (e.g., as measured in accordance with a modified version of ASTM D3161) than conventional starter shingles (c.f., FIG. 2).

[0079] For those inventive starter shingle samples including a reinforcement tape (i.e., Samples 3-8 and 10-11), each starter shingle was nailed to the roof deck assembly using five (5) nails positioned about 2.5 inches from the bottom of the roof deck assembly, while those control starter shingle samples lacking any reinforcement tape (i.e., Samples 1-2 and 9) were nailed to the roof deck assembly using five (5) nails positioned about 2 inches from the bottom of the roof deck assembly. Samples 1-8 were nailed to the roof deck assembly using a nail gun, while Samples 9-11 were manually (hand) nailed to the roof deck assembly. For each of the evaluated samples (i.e., Sample 1-11), similar nails were used.

[0080] The data presented in Table 1 was collected by testing the roof deck with wind perpendicular to the shingle course installation. The roof deck assembly was positioned 7″ from the wind orifice with the drip edge 2″ above the opening of the wind orifice.

[0081] For the control samples (i.e., Sample 1-2 and 9), the Starter Strip Plus shingle made by Owens Corning of Toledo, Ohio was used. Samples 3 and 10 are consistent with exemplary embodiment 300 described herein. Samples 4-8 and 11 are consistent with exemplary embodiment 500 described herein.TABLE 1StarterSampleShingleDrip EdgeUnderlaymentDeck Construction#FeaturesConfigurationTypeSummaryPass / Fail1Control (None)OverFelt3 courses ofFail (15Underlaymentconventionalseconds)shingles installedover the startershingle sample2Control (None)UnderFelt3 courses ofFail (11Underlaymentconventionalminutes)shingles installedover the startershingle sample3ReinforcementOverFelt3 courses ofPass (2tapeUnderlaymentconventionalhours)shingles installedover the startershingle sample4ReinforcementOverFelt3 courses ofPass (2tape; sealantUnderlaymentconventionalhours)shingles installedover the startershingle sample5ReinforcementUnderFelt3 courses ofPass (2tape; sealantUnderlaymentconventionalhours)shingles installedover the startershingle sample6ReinforcementUnderFiberglass mat3 courses ofPass (2tape; sealantUnderlaymentcoated withconventionalhours)asphaltshingles installedover the startershingle sample7ReinforcementUnderPolymeric3 courses ofPass (2tape; sealantUnderlaymentmembraneconventionalhours)coated withshingles installedrubberizedover the starterasphaltshingle sample8ReinforcementUnderSynthetic Roof3 courses ofPass (2tape; sealantUnderlaymentUnderlaymentconventionalhours)shingles installedover the startershingle sample9Control (None)Drip EdgeNoneSingle starterFail (11Onlyshingle onlyseconds)10ReinforcementDrip EdgeNoneSingle starterPass (2tapeOnlyshingle onlyhours)11ReinforcementDrip EdgeNoneSingle starterPass (2tape; sealantOnlyshingle onlyhours)

[0082] In particular, Table 1 shows the pass / fail status for each of the eleven (11) assessed starter shingle and deck configuration assemblies when subjected to simulated wind speeds of 110 mph in accordance with Class F of ASTM D3161. As shown in Table 1, each of the inventive starter shingle samples (i.e., Samples 3-8 and 10-11) passed Class F / 110 mph testing, while each of the control starter shingle samples (i.e., Samples 1-2 and 9) failed Class F / 110 mph testing.

[0083] Furthermore, for the Sample 3 starter shingle, after passing the Class F / 110 mph wind testing for 2 hours, the Sample 3 starter shingle was subjected to 120 mph wind testing for 10 minutes and then 130 mph wind testing for 10 minutes, without failing. For the Sample 4 starter shingle, after passing the Class F / 110 mph wind testing for 2 hours, the Sample 4 starter shingle was subjected to 120 mph wind testing for 10 minutes, 130 mph wind testing for 10 minutes, and then 150 mph wind testing for 10 minutes, without failing. Thus, at least some of the inventive starter shingle samples (e.g., Samples 3-4) were shown capable of withstanding wind speeds of up to at least 150 mph.

[0084] Conversely, the control Sample 1 (having neither a reinforcement tape nor a sealant) failed after only 15 seconds of being subjected to Class F / 110 mph wind testing, with the Sample 1 starter shingle pulling through all five (5) nail fasteners. Similarly, the control Sample 9 (having neither a reinforcement tape nor a sealant) failed after only 11 seconds of being subjected to Class F / 110 mph wind testing, with all five (5) nail fasteners being pulled out of the roof deck assembly.

[0085] The inventive starter shingles disclosed and suggested herein can also contribute to a roofing system that exhibits improved wind resistance over time.

[0086] As shown in Table 2, the wind performance of a roofing system including various starter shingle embodiments was evaluated.

[0087] Each evaluated roofing system included a roof deck constructed and conditioned in accordance with ASTM D3161, with the following exceptions: a drip edge was added at the eave and rake of the roof deck over the felt underlayment; a starter shingle was installed at the eave with a 0.25″ overhang and nailed 2.5″ from the edge of the eave edge; each full starter shingle used 5 nails; the starter shingle at the rake edge was installed in the same manner with the same number of nails; the starter shingle at the rake edge was installed so that it overlapped the starter shingle at the eave; and overlying courses of shingles were installed with 4 nails for each full shingle. In the samples, ten (10) courses of conventional shingles were installed over the starter shingle embodiments.

[0088] For testing purposes, the roof deck was placed 7″ from the wind orifice with the drip edge 2″ above the opening of the wind tunnel. The roof deck was placed at a 45-degree angle relative to the wind tunnel so that both the rake and eave were the target of the testing. The roof deck was tested at a 2:12 slope which is consistent with D3161. The wind testing started at 110 mph and increased in increments of 10 mph up to 160 mph holding for 5 min at each wind speed.

[0089] Four samples were evaluated. For the control samples (i.e., Sample 1-2), the Starter Strip Plus shingle made by Owens Corning of Toledo, Ohio was used as the starter shingle. Samples 3-4 are consistent with exemplary embodiment 500 described herein.TABLE 2StarterSampleShingleDrip EdgeUnderlaymentDeck Construction#FeaturesConfigurationTypeSummaryResult1Control (None)OverFelt10 courses ofFirst course ofUnderlaymentconventionalshinglesshingles installedbecameover the starterunsealed atshingle sample140 mphapproximately1 min 45 secinto testing atthat speed.2Control (None)OverFelt10 courses ofFirst course ofUnderlaymentconventionalshinglesshingles having abecamenail zoneunsealed atreinforcement on150 mphan upper surfaceapproximatelythereof installed5 min intoover the startertesting at thatshingle samplespeed.3ReinforcementOverFelt10 courses ofNo failure oftape; sealantUnderlaymentconventionalthe firstshingles installedcourse ofover the startershinglesshingle sampleobserved upto 160 mphafter 35 minof testing.Testing wasended at the35 min mark.4ReinforcementOverFelt10 courses ofNo failure oftape; sealantUnderlaymentconventionalthe firstshingles having acoursenail zoneobserved upreinforcement onto 160 mphan upper surfaceafter 35 minthereof installedof testing.over the starterTesting wasshingle sampleended at the35 min mark.

[0090] Thus, Table 2 shows improved wind performance representative of an overall roofing system by the inventive starter shingles (i.e., Samples 3-4) as compared to the conventional (control) starter shingles (i.e., Samples 1-2).

[0091] The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. For example, while the exemplary embodiments disclosed herein are described as producing two discrete starter shingles from a single (continuous) sheet of roofing material, one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass each sheet of roofing material forming a single starter shingle or forming more than two (2) starter shingles. As another example, while the exemplary embodiments disclosed herein show the reinforcement member formed on a front side of the starter shingle(s), one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass one or more reinforcement members being formed on a back side of the starter shingle instead of or in addition to any such reinforcement member(s) on the front side. As yet another example, while the exemplary embodiments disclosed herein show the sealant strip extending across a length of the starter shingle, one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass one or more such strips or beads that do not extend the length of the starter shingle and that may be offset from one another in a non-linear fashion within a predefined region (i.e., width) of the starter shingle. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and / or claimed herein, and any equivalents thereof.

Examples

first embodiment

[0058]In a first embodiment, the starter shingle is formed as a single-layer sheet 300, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 3. For production, storage, and / or packaging efficiency, the sheet 300 has a perforated center line 302, which allows the sheet 300 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 300-1 and starter shingle 300-2) prior to installation.

[0059]A front side of the sheet 300 includes a pair of reinforcement members 308, each reinforcement member 308 adjacent to one of the edges of the sheet 300 and each reinforcement member 308 substantially equidistant from the center line 302. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521, each of which is incorporated herein by reference in its entirety.

[0060]The reinforcement...

second embodiment

[0064]In a second embodiment, the starter shingle is formed as a single-layer sheet 400, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 4. For production, storage, and / or packaging efficiency, the sheet 400 has a perforated center line 402, which allows the sheet 400 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 400-1 and starter shingle 400-2) prior to installation.

[0065]A front side of the sheet 400 includes a pair of sealant strips 404, each sealant strip 404 adjacent to one of the edges of the sheet 400 and each sealant strip 404 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) sealant strip 404 on a front side thereof and proximate to one edge thereof. Although the sealant strips 404 in FIG. 4 are shown as a continuous strip / line, the se...

third embodiment

[0071]In a third embodiment, the starter shingle is formed as a single-layer sheet 500, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 5. For production, storage, and / or packaging efficiency, the sheet 500 has a perforated center line 502, which allows the sheet 500 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 500-1 and starter shingle 500-2) prior to installation.

[0072]A front side of the sheet 500 includes a pair of reinforcement members 508, each reinforcement member 508 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0073]The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the rei...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application No. 63 / 765,012, filed on Feb. 28, 2025, the entire disclosure of which is fully incorporated herein by reference.FIELD

[0002] The inventive concepts generally relate to roofing shingles and, in particular, to starter shingles having improved wind resistance.BACKGROUND

[0003] Asphalt-based roofing materials, such as roofing shingles, are installed on the roofs of buildings to provide protection from the elements, and to give the roof an aesthetically pleasing look. Typically, a roofing shingle is constructed of a substrate such as a glass fiber mat or an organic felt, an asphalt coating on the substrate, and a surface layer of granules embedded in the asphalt coating. The shingle constructions may include one or more layers.

[0004] It is known to install roofing shingles (e.g., laminated asphalt shingles) on a sloped roof deck in horizontal layers referred to as “courses” of shingles. Each subsequent course of shingles partially overlaps with the course immediately below it, thereby forming an overlapping shingled surface that facilitates removal of water from the roof. Installation of the shingles starts at the bottom (eave region) of the roof and extends upwards (one course at a time) until reaching or approaching the top (ridge region) of the roof, as shown in FIG. 1A. This installation direction is represented by the dashed line Id in FIG. 1A. A portion of a course that extends past the rake of the roof can simply be cut off.

[0005] The roof deck may include additional structure / materials (e.g., underlayment(s)) applied thereto prior to installation of the shingles, as shown in Detail A of FIG. 1B. For example, the roof deck will typically include a drip edge, which is an L-shaped metal flashing that is installed along the eaves and rakes to direct water away from the fascia to prevent wood rot, deck damage, and pest intrusion. In some cases the drip edge is installed under the underlayment, while in other cases the drip edge is installed over the underlayment.

[0006] Because the first course of shingles do not have a lower course to overlap, a special type of shingle (called a starter and / or strip shingle) is used. The Starter Strip Plus Shingle made by Owens Corning of Toledo, Ohio is one such product.

[0007] Consequently, the dimensions of the starter shingles (e.g., 7¾″×39⅜″ (197 mm×1,000 mm)) are typically narrower than the laminated shingles (e.g., 13¼″×39⅜″ (337 mm×1,000 mm)) that make up the remaining courses of installed shingles. In general, the entire course of starter shingles are covered by the subsequent course of laminated shingles.

[0008] A conventional starter shingle has a relatively simple construction, a (front and back) plan view of which is shown in FIG. 2. See also U.S. Pat. No. 6,199,338, the entire disclosure of which is incorporated herein by reference.

[0009] In particular, the starter shingle is formed as a single-layer sheet 200, which can be formed of the same materials found in a laminated shingle (e.g., a non-woven fiberglass mat coated / impregnated with asphalt). For production, storage, and / or packaging efficiency, the sheet 200 has a perforated center line 202, which allows the sheet 200 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 200-1 and starter shingle 200-2) prior to installation.

[0010] A front side of the sheet 200 includes a pair of sealant strips 204, each sealant strip 204 adjacent to one of the edges of the sheet 200 and each sealant strip 204 substantially equidistant from the center line 202. In this manner, each of starter shingle 200-1 and 200-2 will have one (1) sealant strip 204 on a front side thereof and proximate to one edge thereof. Although the sealant strips 204 in FIG. 2 are shown as a continuous strip / line, the sealant 204 can be applied in a discontinuous manner across a length of the sheet 200.

[0011] Similarly, a back side of the sheet 200 includes a pair of release tapes 206, each release tape 206 adjacent to one of the edges of the sheet 200 and each release tape 206 substantially equidistant from the center line 202. In this manner, each of starter shingle 200-1 and 200-2 will have one (1) release tape 206 on a back side thereof and proximate to one edge thereof.

[0012] The release tapes 206 on the sheet 200 function to prevent one sheet 200 from sticking to another sheet 200, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 204 of one sheet (front) facing the release tapes 206 of the other sheet (back). To facilitate this functioning, a width of the release tapes 206 can be greater than a width of the sealants 204. Furthermore, each of the sealants 204 and the release tapes 206 are offset from their respective edges of the sheets 200 by a distance that promotes alignment thereof when stacked.

[0013] The starter shingles 200-1, 200-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the sealant strip 204 of each starter shingle closer to the bottom of the roof deck. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed slightly past the sealant strip 204 in each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck. The sealant strip 204 of each starter shingle adheres to an overlapping shingle installed over the starting shingle.

[0014] In assessing the performance of shingles (in particular, to estimate performance of a shingle in an installed state), the ability of the shingle to resist damage from wind, such as that resulting from failure of the sealant, is an important property.

[0015] ASTM D3161 is a standard test method for assessing wind resistance of asphalt shingles. There are three classes of wind performance in this test, Class A / 60 mph, Class B / 90 mph, and Class F / 110 mph. It is more desirable for shingles to achieve the Class F wind rating. The testing requires a deck to be constructed at a 2:12 slope and products installed per the manufacturer's instructions. After conditioning at 140° F. for 16 hours, the test decks are then exposed to the wind velocities for a given class rating, with wind perpendicular to the shingle course installation. The test runs for 2 hours, and if the shingle tabs uplift from the deck or show any signs of permanent damage, they are deemed a failure. If the roofing assembly prevents full tabs from lifting up for the 2-hour duration, it is considered a pass.

[0016] One of the challenges with D3161 wind testing is that it does not include specific provisions for starter / strip shingles, which might be referred to as non-standard or accessory shingles. Due to the location and configuration of these shingle accessory products, there is not any language or guidance on how to specifically conduct D3161 testing. This is a known issue in the industry for wind certification of accessory products. The present invention addresses this issue.SUMMARY

[0017] The general inventive concepts relate to improved starter shingles and other shingle accessory products. The inventive starter shingles have modified designs, such that the inventive starter shingles are more likely to directly pass D3161 wind performance testing standards (particularly Class F / 110 mph), as modified to address shingle accessory products, than conventional starter shingles.

[0018] In one exemplary embodiment (a), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; and wherein the front side of the starter shingle includes a reinforcement member that is parallel to an edge of the starter shingle.

[0019] In some exemplary embodiments (based on (a)), the starter shingle has a single layer of the asphalt-coated substrate.

[0020] In some exemplary embodiments (based on (a)), the substrate is a non-woven fiberglass mat.

[0021] In some exemplary embodiments (based on (a)), the reinforcement member is a polyester tape.

[0022] In some exemplary embodiments (based on (a)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0023] In some exemplary embodiments (based on (a)), a gap between the reinforcement member and the edge of the starter shingle is at least 1 inch wide.

[0024] In some exemplary embodiments (based on (a)), the reinforcement member is continuous and extends a length of the starter shingle.

[0025] In one exemplary embodiment (b), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is in proximity to and parallel to a first edge of the starter shingle; wherein the front side of the starter shingle includes a strip of a sealant material that is situated between the reinforcement member and the first edge and that is parallel to the first edge; and wherein the back side of the starter shingle includes a release tape that is in proximity to and parallel to a second edge of the starter shingle.

[0026] In some exemplary embodiments (based on (b)), the starter shingle has a single layer of the asphalt-coated substrate.

[0027] In some exemplary embodiments (based on (b)), the substrate is a non-woven fiberglass mat.

[0028] In some exemplary embodiments (based on (b)), the reinforcement member is a polyester tape.

[0029] In some exemplary embodiments (based on (b)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0030] In some exemplary embodiments (based on (b)), a gap between the reinforcement member and the first edge of the starter shingle is at least 1 inch wide.

[0031] In some exemplary embodiments (based on (b)), the reinforcement member is continuous and extends a length of the starter shingle.

[0032] In some exemplary embodiments (based on (b)), the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

[0033] In some exemplary embodiments (based on (b)), a gap between the strip of the sealant member and the first edge of the starter shingle is less than 2 inches wide.

[0034] In some exemplary embodiments (based on (b)), the release tape is continuous and extends a length of the starter shingle.

[0035] In some exemplary embodiments (based on (b)), a gap between the release tape and the second edge of the starter shingle is less than 2 inches wide.

[0036] In one exemplary embodiment (c), a starter shingle for installation on a roof deck is disclosed. The starter shingle comprises at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is parallel to a first edge of the starter shingle; and wherein the back side of the starter shingle includes a strip of a sealant material that is in proximity to and parallel to a second edge of the starter shingle.

[0037] In some exemplary embodiments (based on (c)), the starter shingle has a single layer of the asphalt-coated substrate.

[0038] In some exemplary embodiments (based on (c)), the substrate is a non-woven fiberglass mat.

[0039] In some exemplary embodiments (based on (c)), the reinforcement member is a polyester tape.

[0040] In some exemplary embodiments (based on (c)), a width of the reinforcement member is less than 15% of a width of the starter shingle.

[0041] In some exemplary embodiments (based on (c)), a gap between the reinforcement member and the first edge of the starter shingle is at least 1 inch wide.

[0042] In some exemplary embodiments (based on (c)), the reinforcement member is continuous and extends a length of the starter shingle.

[0043] In some exemplary embodiments (based on (c)), the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

[0044] In some exemplary embodiments (based on (c)), a gap between the strip of the sealant member and the second edge of the starter shingle is less than 2 inches wide.

[0045] In one exemplary embodiment (d), a roofing system comprises a plurality of starter shingles (e.g., based on (a), (b), and / or (c)), wherein the starter shingles are installed adjacent to one another along at least one of an eave and a rake of a roof deck; and wherein a plurality of shingles are installed adjacent to one another on the roof deck, said shingles at least partially overlapping the starter shingles.

[0046] In some exemplary embodiments (based on (d)), the shingles can withstand wind speeds greater than or equal to 110 mph for at least 2 hours.

[0047] In some exemplary embodiments (based on (d)), the shingles can withstand wind speeds greater than or equal to 160 mph for at least 35 minutes.

[0048] Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

[0050] FIGS. 1A and 1B illustrate a roof where shingles could be installed. FIG. 1A is a diagram of a sloped roof. FIG. 1B is a detailed view of a portion of the sloped roof of FIG. 1A, where a starter shingle would be installed.

[0051] FIG. 2 illustrates a conventional starter shingle by providing a front plan view and back plan view of the conventional starter shingle.

[0052] FIG. 3 illustrates a starter shingle according to a first exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.

[0053] FIG. 4 illustrates a starter shingle according to a second exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.

[0054] FIG. 5 illustrates a starter shingle according to a third exemplary embodiment of the present invention by providing a front plan view and back plan view of the inventive starter shingle.DETAILED DESCRIPTION

[0055] Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

[0056] Because there is concern that the conventional starter shingle (shown in FIG. 2) may not pass the D3161 testing should the standard be modified to specifically provide for testing of shingle accessory products, various modified starter shingle embodiments were developed to have an improved chance of passing the D3161-type testing (i.e., that are expected to have improved wind resistance). Three such exemplary embodiments are shown in FIGS. 3-5, respectively.

[0057] Accordingly, the general inventive concepts encompass improved starter shingle constructions, which are more likely to directly pass D3161 wind performance testing standards (particularly Class F / 110 mph) than conventional starter shingles. Consequently, a shingle manufacturer need not resort to the industry practice of attributing the D3161 wind performance of regular shingles to related shingle accessory products (e.g., starter shingles). Instead, the starter shingles are able to pass such testing on their own.

[0058] In a first embodiment, the starter shingle is formed as a single-layer sheet 300, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 3. For production, storage, and / or packaging efficiency, the sheet 300 has a perforated center line 302, which allows the sheet 300 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 300-1 and starter shingle 300-2) prior to installation.

[0059] A front side of the sheet 300 includes a pair of reinforcement members 308, each reinforcement member 308 adjacent to one of the edges of the sheet 300 and each reinforcement member 308 substantially equidistant from the center line 302. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521, each of which is incorporated herein by reference in its entirety.

[0060] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0061] There are no other structural features (e.g., sealant strips, release tapes) added to either side of the starter shingle in this embodiment. In particular, this embodiment relies on a sealant on an underside of shingles to be installed in the next course of shingles (i.e., overlapping the starting shingles 300-1, 300-2, etc.) to bond those shingles with the starter shingles.

[0062] Because there are no sealant strips on the starter shingles of this embodiment, the starter shingles can be readily stacked on one another.

[0063] The starter shingles 300-1, 300-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the reinforcement members 308 of each starter shingle closer to the bottom of the roof deck. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed within the reinforcement members 308 across a length of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck.

[0064] In a second embodiment, the starter shingle is formed as a single-layer sheet 400, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 4. For production, storage, and / or packaging efficiency, the sheet 400 has a perforated center line 402, which allows the sheet 400 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 400-1 and starter shingle 400-2) prior to installation.

[0065] A front side of the sheet 400 includes a pair of sealant strips 404, each sealant strip 404 adjacent to one of the edges of the sheet 400 and each sealant strip 404 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) sealant strip 404 on a front side thereof and proximate to one edge thereof. Although the sealant strips 404 in FIG. 4 are shown as a continuous strip / line, the sealant 404 can be applied in a discontinuous manner across a length of the sheet 400. Here, the composition and location of the sealant 404 can be the same as with the conventional starter shingles shown in FIG. 2.

[0066] The front side of the sheet 400 also includes a pair of reinforcement members 408, each reinforcement member 408 adjacent to one of the edges of the sheet 400, each reinforcement member 408 further from its respective edge than the aforementioned sealant strip 404, and each reinforcement member 408 substantially equidistant from the center line 402. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0067] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0068] A back side of the sheet 400 includes a pair of release tapes 406, each release tape 406 adjacent to one of the edges of the sheet 400 and each release tape 406 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) release tape 406 on a back side thereof and proximate to one edge thereof.

[0069] The release tapes 406 on the sheet 400 function to prevent one sheet 400 from sticking to another sheet 400, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 404 of one sheet (front) facing the release tapes 406 of the other sheet (back). To facilitate this functioning, a width of the release tapes 406 can be greater than a width of the sealants 404. Furthermore, each of the sealants 404 and the release tapes 406 are offset from their respective edges of the sheets 400 by a distance that promotes alignment thereof when stacked.

[0070] The starter shingles 400-1, 400-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1A) with the sealant strip 404 of each starter shingle closer to the bottom of the roof deck than the corresponding reinforcement member 408. In particular, a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed past the sealant strip 404 in the reinforcement member 408 of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to secure the starter shingle to the roof deck. Then, the sealant strip 404 would bond with an overlying shingle installed over the starter shingle.

[0071] In a third embodiment, the starter shingle is formed as a single-layer sheet 500, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 5. For production, storage, and / or packaging efficiency, the sheet 500 has a perforated center line 502, which allows the sheet 500 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 500-1 and starter shingle 500-2) prior to installation.

[0072] A front side of the sheet 500 includes a pair of reinforcement members 508, each reinforcement member 508 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0073] The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the reinforcement member has a width less than 15% of the width of the starter shingle.

[0074] A back side of the sheet 500 includes a pair of sealant strips 504, each sealant strip 504 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. In this manner, each of starter shingle 500-1 and 500-2 will have one (1) sealant strip 504 on a back side thereof and proximate to one edge thereof. Although the sealant strips 504 in FIG. 5 are shown as a continuous strip / line, the sealant 504 can be applied in a discontinuous manner across a length of the sheet 500. Here, the composition of the sealant 504 can be the same as with the conventional starter shingles shown in FIG. 2.

[0075] The back side of the sheet 500 also includes a pair of release tapes 506, each release tape 506 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. In this manner, each of starter shingle 500-1 and 500-2 will have one (1) release tape 506 on a back side thereof and proximate to one edge thereof.

[0076] The release tapes 506 on the sheet 500 function to prevent one sheet 500 from sticking to another sheet 500, when both sheets are stacked (e.g., for packaging) on top of one another with the sealants 504 of one sheet (back) facing the release tapes 506 of the other sheet (back, turned 180 degrees). To facilitate this functioning, a width of the release tapes 506 can be greater than a width of the sealants 504. Furthermore, each of the sealants 504 and the release tapes 506 are offset from their respective edges of the sheets 500 by a distance that promotes alignment thereof when stacked.

[0077] The starter shingles 500-1, 500-2, etc. are installed at the bottom of the roof deck in the eave region (see FIG. 1) with the sealant strip 504 of each starter shingle closer to the bottom of the roof deck than the corresponding reinforcement member 508. In particular, the sealant 504 is adhered to the roof deck (including any intervening structure, such as an underlayment) and then a predetermined / recommended number of fasteners (e.g., five (5) nails) are placed in the reinforcement member 508 of each starter shingle (i.e., at least about 2 inches (51 mm) from the bottom edge of the starter shingle) to further secure the starter shingle to the roof deck.

[0078] As shown in Table 1, each starter shingle of Embodiment 1, Embodiment 2, and Embodiment 3 were shown to exhibit improved wind resistance (e.g., as measured in accordance with a modified version of ASTM D3161) than conventional starter shingles (c.f., FIG. 2).

[0079] For those inventive starter shingle samples including a reinforcement tape (i.e., Samples 3-8 and 10-11), each starter shingle was nailed to the roof deck assembly using five (5) nails positioned about 2.5 inches from the bottom of the roof deck assembly, while those control starter shingle samples lacking any reinforcement tape (i.e., Samples 1-2 and 9) were nailed to the roof deck assembly using five (5) nails positioned about 2 inches from the bottom of the roof deck assembly. Samples 1-8 were nailed to the roof deck assembly using a nail gun, while Samples 9-11 were manually (hand) nailed to the roof deck assembly. For each of the evaluated samples (i.e., Sample 1-11), similar nails were used.

[0080] The data presented in Table 1 was collected by testing the roof deck with wind perpendicular to the shingle course installation. The roof deck assembly was positioned 7″ from the wind orifice with the drip edge 2″ above the opening of the wind orifice.

[0081] For the control samples (i.e., Sample 1-2 and 9), the Starter Strip Plus shingle made by Owens Corning of Toledo, Ohio was used. Samples 3 and 10 are consistent with exemplary embodiment 300 described herein. Samples 4-8 and 11 are consistent with exemplary embodiment 500 described herein.TABLE 1StarterSampleShingleDrip EdgeUnderlaymentDeck Construction#FeaturesConfigurationTypeSummaryPass / Fail1Control (None)OverFelt3 courses ofFail (15Underlaymentconventionalseconds)shingles installedover the startershingle sample2Control (None)UnderFelt3 courses ofFail (11Underlaymentconventionalminutes)shingles installedover the startershingle sample3ReinforcementOverFelt3 courses ofPass (2tapeUnderlaymentconventionalhours)shingles installedover the startershingle sample4ReinforcementOverFelt3 courses ofPass (2tape; sealantUnderlaymentconventionalhours)shingles installedover the startershingle sample5ReinforcementUnderFelt3 courses ofPass (2tape; sealantUnderlaymentconventionalhours)shingles installedover the startershingle sample6ReinforcementUnderFiberglass mat3 courses ofPass (2tape; sealantUnderlaymentcoated withconventionalhours)asphaltshingles installedover the startershingle sample7ReinforcementUnderPolymeric3 courses ofPass (2tape; sealantUnderlaymentmembraneconventionalhours)coated withshingles installedrubberizedover the starterasphaltshingle sample8ReinforcementUnderSynthetic Roof3 courses ofPass (2tape; sealantUnderlaymentUnderlaymentconventionalhours)shingles installedover the startershingle sample9Control (None)Drip EdgeNoneSingle starterFail (11Onlyshingle onlyseconds)10ReinforcementDrip EdgeNoneSingle starterPass (2tapeOnlyshingle onlyhours)11ReinforcementDrip EdgeNoneSingle starterPass (2tape; sealantOnlyshingle onlyhours)

[0082] In particular, Table 1 shows the pass / fail status for each of the eleven (11) assessed starter shingle and deck configuration assemblies when subjected to simulated wind speeds of 110 mph in accordance with Class F of ASTM D3161. As shown in Table 1, each of the inventive starter shingle samples (i.e., Samples 3-8 and 10-11) passed Class F / 110 mph testing, while each of the control starter shingle samples (i.e., Samples 1-2 and 9) failed Class F / 110 mph testing.

[0083] Furthermore, for the Sample 3 starter shingle, after passing the Class F / 110 mph wind testing for 2 hours, the Sample 3 starter shingle was subjected to 120 mph wind testing for 10 minutes and then 130 mph wind testing for 10 minutes, without failing. For the Sample 4 starter shingle, after passing the Class F / 110 mph wind testing for 2 hours, the Sample 4 starter shingle was subjected to 120 mph wind testing for 10 minutes, 130 mph wind testing for 10 minutes, and then 150 mph wind testing for 10 minutes, without failing. Thus, at least some of the inventive starter shingle samples (e.g., Samples 3-4) were shown capable of withstanding wind speeds of up to at least 150 mph.

[0084] Conversely, the control Sample 1 (having neither a reinforcement tape nor a sealant) failed after only 15 seconds of being subjected to Class F / 110 mph wind testing, with the Sample 1 starter shingle pulling through all five (5) nail fasteners. Similarly, the control Sample 9 (having neither a reinforcement tape nor a sealant) failed after only 11 seconds of being subjected to Class F / 110 mph wind testing, with all five (5) nail fasteners being pulled out of the roof deck assembly.

[0085] The inventive starter shingles disclosed and suggested herein can also contribute to a roofing system that exhibits improved wind resistance over time.

[0086] As shown in Table 2, the wind performance of a roofing system including various starter shingle embodiments was evaluated.

[0087] Each evaluated roofing system included a roof deck constructed and conditioned in accordance with ASTM D3161, with the following exceptions: a drip edge was added at the eave and rake of the roof deck over the felt underlayment; a starter shingle was installed at the eave with a 0.25″ overhang and nailed 2.5″ from the edge of the eave edge; each full starter shingle used 5 nails; the starter shingle at the rake edge was installed in the same manner with the same number of nails; the starter shingle at the rake edge was installed so that it overlapped the starter shingle at the eave; and overlying courses of shingles were installed with 4 nails for each full shingle. In the samples, ten (10) courses of conventional shingles were installed over the starter shingle embodiments.

[0088] For testing purposes, the roof deck was placed 7″ from the wind orifice with the drip edge 2″ above the opening of the wind tunnel. The roof deck was placed at a 45-degree angle relative to the wind tunnel so that both the rake and eave were the target of the testing. The roof deck was tested at a 2:12 slope which is consistent with D3161. The wind testing started at 110 mph and increased in increments of 10 mph up to 160 mph holding for 5 min at each wind speed.

[0089] Four samples were evaluated. For the control samples (i.e., Sample 1-2), the Starter Strip Plus shingle made by Owens Corning of Toledo, Ohio was used as the starter shingle. Samples 3-4 are consistent with exemplary embodiment 500 described herein.TABLE 2StarterSampleShingleDrip EdgeUnderlaymentDeck Construction#FeaturesConfigurationTypeSummaryResult1Control (None)OverFelt10 courses ofFirst course ofUnderlaymentconventionalshinglesshingles installedbecameover the starterunsealed atshingle sample140 mphapproximately1 min 45 secinto testing atthat speed.2Control (None)OverFelt10 courses ofFirst course ofUnderlaymentconventionalshinglesshingles having abecamenail zoneunsealed atreinforcement on150 mphan upper surfaceapproximatelythereof installed5 min intoover the startertesting at thatshingle samplespeed.3ReinforcementOverFelt10 courses ofNo failure oftape; sealantUnderlaymentconventionalthe firstshingles installedcourse ofover the startershinglesshingle sampleobserved upto 160 mphafter 35 minof testing.Testing wasended at the35 min mark.4ReinforcementOverFelt10 courses ofNo failure oftape; sealantUnderlaymentconventionalthe firstshingles having acoursenail zoneobserved upreinforcement onto 160 mphan upper surfaceafter 35 minthereof installedof testing.over the starterTesting wasshingle sampleended at the35 min mark.

[0090] Thus, Table 2 shows improved wind performance representative of an overall roofing system by the inventive starter shingles (i.e., Samples 3-4) as compared to the conventional (control) starter shingles (i.e., Samples 1-2).

[0091] The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. For example, while the exemplary embodiments disclosed herein are described as producing two discrete starter shingles from a single (continuous) sheet of roofing material, one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass each sheet of roofing material forming a single starter shingle or forming more than two (2) starter shingles. As another example, while the exemplary embodiments disclosed herein show the reinforcement member formed on a front side of the starter shingle(s), one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass one or more reinforcement members being formed on a back side of the starter shingle instead of or in addition to any such reinforcement member(s) on the front side. As yet another example, while the exemplary embodiments disclosed herein show the sealant strip extending across a length of the starter shingle, one of ordinary skill in the art will appreciate that the general inventive concepts would also encompass one or more such strips or beads that do not extend the length of the starter shingle and that may be offset from one another in a non-linear fashion within a predefined region (i.e., width) of the starter shingle. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and / or claimed herein, and any equivalents thereof.

Examples

first embodiment

[0058]In a first embodiment, the starter shingle is formed as a single-layer sheet 300, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 3. For production, storage, and / or packaging efficiency, the sheet 300 has a perforated center line 302, which allows the sheet 300 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 300-1 and starter shingle 300-2) prior to installation.

[0059]A front side of the sheet 300 includes a pair of reinforcement members 308, each reinforcement member 308 adjacent to one of the edges of the sheet 300 and each reinforcement member 308 substantially equidistant from the center line 302. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521, each of which is incorporated herein by reference in its entirety.

[0060]The reinforcement...

second embodiment

[0064]In a second embodiment, the starter shingle is formed as a single-layer sheet 400, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 4. For production, storage, and / or packaging efficiency, the sheet 400 has a perforated center line 402, which allows the sheet 400 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 400-1 and starter shingle 400-2) prior to installation.

[0065]A front side of the sheet 400 includes a pair of sealant strips 404, each sealant strip 404 adjacent to one of the edges of the sheet 400 and each sealant strip 404 substantially equidistant from the center line 402. In this manner, each of starter shingle 400-1 and 400-2 will have one (1) sealant strip 404 on a front side thereof and proximate to one edge thereof. Although the sealant strips 404 in FIG. 4 are shown as a continuous strip / line, the se...

third embodiment

[0071]In a third embodiment, the starter shingle is formed as a single-layer sheet 500, which can be formed of the same materials found in conventional starter shingles (e.g., a non-woven fiberglass mat coated / impregnated with asphalt), as shown in FIG. 5. For production, storage, and / or packaging efficiency, the sheet 500 has a perforated center line 502, which allows the sheet 500 to be manually separated into two (2) discrete starter shingle portions (i.e., starter shingle 500-1 and starter shingle 500-2) prior to installation.

[0072]A front side of the sheet 500 includes a pair of reinforcement members 508, each reinforcement member 508 adjacent to one of the edges of one of the starter shingles 500-1, 500-2. Such reinforcement members (e.g., fabrics, tapes, films) are described, for example, in U.S. Pat. Nos. 7,836,654 and 8,607,521.

[0073]The reinforcement member will typically have a width less than 25% of the width of the starter shingle. In some exemplary embodiments, the rei...

Claims

1. A starter shingle for installation on a roof deck, the starter shingle comprising at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; and wherein the front side of the starter shingle includes a reinforcement member that is parallel to an edge of the starter shingle.

2. The starter shingle of claim 1, wherein the starter shingle has a single layer of the asphalt-coated substrate.

3. The starter shingle of claim 1, wherein the substrate is a non-woven fiberglass mat.

4. The starter shingle of claim 1, wherein the reinforcement member is a polyester tape.

5. The starter shingle of claim 1, wherein the reinforcement member is continuous and extends a length of the starter shingle.

6. A starter shingle for installation on a roof deck, the starter shingle comprising at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is in proximity to and parallel to a first edge of the starter shingle; wherein the front side of the starter shingle includes a strip of a sealant material that is situated between the reinforcement member and the first edge and that is parallel to the first edge; and wherein the back side of the starter shingle includes a release tape that is in proximity to and parallel to a second edge of the starter shingle.

7. The starter shingle of claim 6, wherein the starter shingle has a single layer of the asphalt-coated substrate.

8. The starter shingle of claim 6, wherein the substrate is a non-woven fiberglass mat.

9. The starter shingle of claim 6, wherein the reinforcement member is a polyester tape.

10. The starter shingle of claim 6, wherein the reinforcement member is continuous and extends a length of the starter shingle.

11. The starter shingle of claim 6, wherein the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

12. The starter shingle of claim 6, wherein a gap between the strip of the sealant member and the first edge of the starter shingle is less than 2 inches wide.

13. The starter shingle of claim 6, wherein the release tape is continuous and extends a length of the starter shingle.

14. The starter shingle of claim 6, wherein a gap between the release tape and the second edge of the starter shingle is less than 2 inches wide.

15. A starter shingle for installation on a roof deck, the starter shingle comprising at least one layer of an asphalt-coated substrate, wherein the starter shingle has a front side intended to face away from the roof deck when installed thereon and a back side intended to face toward the roof deck when installed thereon; wherein the front side of the starter shingle includes a reinforcement member that is parallel to a first edge of the starter shingle; and wherein the back side of the starter shingle includes a strip of a sealant material that is in proximity to and parallel to a second edge of the starter shingle.

16. The starter shingle of claim 15, wherein the starter shingle has a single layer of the asphalt-coated substrate.

17. The starter shingle of claim 15, wherein the substrate is a non-woven fiberglass mat.

18. The starter shingle of claim 15, wherein the reinforcement member is a polyester tape.

19. The starter shingle of claim 15, wherein the reinforcement member is continuous and extends a length of the starter shingle.

20. The starter shingle of claim 15, wherein the strip of the sealant material comprises a plurality of discontinuous strips extending between opposing sides of the starter shingle.

21. The starter shingle of claim 15, wherein a gap between the strip of the sealant member and the second edge of the starter shingle is less than 2 inches wide.

22. A roofing system comprising a plurality of starter shingles according to claim 1,wherein the starter shingles are installed adjacent to one another along at least one of an eave and a rake of a roof deck; andwherein a plurality of shingles are installed adjacent to one another on the roof deck, said shingles at least partially overlapping the starter shingles.

23. The roofing system of claim 22, wherein the shingles can withstand wind speeds greater than or equal to 110 mph for at least 2 hours.

24. The roofing system of claim 22, wherein the shingles can withstand wind speeds greater than or equal to 160 mph for at least 35 minutes.

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