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(12) Patent Application Publication (10) Pub. No.: US 2005/0252141 A1 Kerkar Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2005/0252141 A1 Kerkar Et Al US 2005O2521.41A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2005/0252141 A1 Kerkar et al. (43) Pub. Date: Nov. 17, 2005 (54) ROOFING SHINGLES PROVIDED WITH (22) Filed: Mar. 30, 2004 RELEASE COATING Publication Classification (75) Inventors: Awdhoot Vasant Kerkar, Rockaway, NJ (US); Tommy Rodrigues, Union, (51) Int. Cl." ....................................................... E04D 1/34 NJ (US); Frederick W. Sieling, Bound (52) U.S. Cl. ................................................................ 52/551 Brook, NJ (US) Correspondence Address: (57) ABSTRACT GAF MATERIALS CORPORATION Attn: William J. Davis, Esq. Legal Department, Building No. 10 A roofing shingle and a method of manufacturing roofing 1361 Alps Raod shingle wherein the bottom Surface of Said shingle is pro Wayne, NJ 07470 (US) Vided with a release coating of a continuous film of particles having poor interlaminar Strength due to the particles having (73) Assignee: BUILDING MATERIALS INVEST. good to perfect basal cleavage. The release coating Signifi MENT CORPORATION cantly eases Separation of roofing shingles that Stick together when Stacked during Storage and transit in warm environ (21) Appl. No.: 10/812,541 mentS. Patent Application Publication Nov. 17, 2005 US 2005/0252141 A1 Fig. 1 Fig. 2 US 2005/0252141 A1 Nov. 17, 2005 ROOFING SHINGLES PROVIDED WITH climates when temperatures approach the Softening point of RELEASE COATING the Shingle asphalt coating, resulting in asphalt flow. The Sticking is also a function of time where longer periods of BACKGROUND OF THE INVENTION compression time increase the Sticking. The combination of 0001) 1. Field of the Invention high temperature and long Storage times results in very damaging Sticking. Mechanical interlock of asphalt within 0002 The present invention is directed to roofing the granules under the effect of the pressure point also shingles provided with a release coating. More Specifically, contributes to the Sticking phenomenon. the present invention focuses upon laminated roofing shingles whose bottom Surface is coated with a continuous 0009. The problem discussed above has been recognized film of release material characterized by poor interlaminar in the art. Among the expedients attempted to overcome this Strength. problem has been the application of a plastic release tape, positioned in the pressure point region of each shingle. This 0003 2. Background of the Prior Art method has been Successful, albeit not 100% effective. Not 0004 Roofing shingles are often divided into two main only is this method not totally effective but, in addition, groups: Strip shingles and dimensional or laminated application of release tape adds significant material and shingles. The most common type of roofing shingles are labor expense. laminated. These laminated shingles, often referred to as 0010. The failure to find a complete solution to the “architectural shingles, include a top layer, which those problem of Sticking together of roofing shingles when skilled in the art speak of as the “anterior layer” and a bottom Stacked in Stacks of a plurality of roofing shingles and layer, referred to as the “posterior layer.” The back surface disposed on pallets during shipping and Storage of roofing of the anterior layer is bonded to the front surface of the shingles prior to installation on building roofs evidences the posterior layer. The posterior layer is bonded So that it mates need in the art for a new roofing shingle which overcomes with the lower butt portion of the anterior layer and further this problem. The solution to this problem is constrained by overlaps the anterior layer over a fraction of the undivided the need to retain the roofing shingle design that has proven headlap portion. effective in protecting roofs. 0005 Strip shingles are also prevalent. Strip shingles are Single layer asphalt shingles that are manufactured in Strips, BRIEF SUMMARY OF THE INVENTION typically three times as long as they are wide. 0.011) A new roofing shingle has now been developed 0006 A problem associated with both laminated and strip which overcomes the problem of Sticking together of roofing roofing shingles lies in Shipment and Storage of these shingles, when Stacked in a plurality of roofing shingles and shingles. Shingles are packaged in bundles of 20 to 25 disposed on pallets, during transit and Storage. This new shingles. Laminated shingles are bundled in either alternat shingle design does not adversely affect roofing Shingle ing anterior layer to anterior layer and posterior layer to performance in protecting roofs and represents a minimal posterior layer configuration or each shingle is Stacked one additional expense in terms of additional processing com atop another So that the anterior layer of a first shingle faces plexity and component cost. the posterior layer of the adjoining shingle, that is, front 0012. In accordance with the present invention a new Surface-to-front Surface, back Surface-to-back Surface or roofing shingle has been developed. The Shingles of this front Surface-to-back Surface. Furthermore, the bundles are invention include mono- and multiply types as in a roll on typically Stacked and palletized in independent columns or sheet used for built up roofing and also includes individual in an interwoven “E” pattern. shingles of the tabbed variety which in turn includes mono 0007 Independent of the bundling method, the high layered and composite types having a headlap portion and a preSSure caused by Stacking of these heavy roofing shingles, tabbed portion with or without a backer strip underlying the causes the shingles to Stick together. Additionally, there is a tabs. The Shingle includes a Surface coated with a release transition region found in many laminated Shingles due to coating. the posterior layer having a Smaller width than the anterior 0013 In accordance with the present invention a new layer added thickness caused by the overlapping Shingle method of manufacturing a roofing shingle is disclosed. The layers in laminated shingles creates a hump. This transition method provides for applying a release coating to the Shingle region is most often characterized by a stepped profile. The during manufacture. Stepped transition region located at the Sharp transition in thickness between the top portion of the anterior layer, BRIEF DESCRIPTION OF THE DRAWINGS which is unbonded, and the portion of that layer bonded to the posterior layer, results in a pressure point within the 0014. The present invention may be better understood by Stack. The pallet arrangements magnify the pressure reference to the accompanying drawings of which: observed in a Single Stack. AS Such, preSSure at the preSSure 0.015 FIG. 1 is a view of the top surface of a laminated point of each shingle is magnified. This pressure point roofing shingle in accordance with the present invention; results in distortion and localized Sticking of the shingles. 0016 FIG. 2 is a view of the bottom surface of the The degree of Sticking together of adjoining shingles is roofing shingle of FIG. 1 in accordance with the present proportional to load, which imparts pressures. Thus, invention. shingles at the bottom of a Stack are more prone to Sticking than those at the top where the pressure is lower. DETAILED DESCRIPTION 0008. The sticking together of roofing shingles is 0017. The following detailed description of the invention observed predominantly during warmer months and in hotter is to a 2-ply laminated shingle for convenience but the US 2005/0252141 A1 Nov. 17, 2005 invention is not limited to Such a shingle. The roofing 0026 Bannisterite (Hydrated Potassium Calcium shingle 1 in accordance with the present invention is Manganese Iron Zinc Aluminum Silicate Hydrox depicted as it appears viewed from its top surface in FIG. 1 ide); and from its bottom surface in FIG. 2. The roofing shingle is preferably a laminate of an anterior layer 2 having a front 0027 Carletonite (Hydrated Potassium Sodium Cal Surface and a back Surface and posterior layer 5 having a cium Silicate Carbonate Hydroxide Fluoride); front Surface and a back Surface. The anterior layer includes 0028 Cavansite (Hydrated Calcium Vanadate Sili an undivided headlap portion 3 and a lower butt portion 4. cate); The posterior layer 5, often referred to in the art as a “backer Strip, is usually rectangularly shaped. The front Surface of 0029 Chrysocolla (Hydrated Copper Aluminum the posterior layer 5 is bonded to the back surface of the Hydrogen Silicate Hydroxide); anterior layer 2 So that it completely mates with the lower 0030 Baileychlore (Zinc Iron Aluminum Magne butt portion 4 and provides an overlap of the two layers over sium Silicate Hydroxide); a fraction of the undivided headlap portion 3. However, the 0031 Chamosite (Iron Magnesium Aluminum Sili shingle may be mono-layered or have three or more layers. cate Hydroxide Oxide); Chlorite; 0.018. Both the anterior layer 2 and the posterior layer 5 preferably comprise a fiberglass mat, an organic or inorganic 0032) Clinochlore (Iron Magnesium Aluminum Sili felt or fabric Stock impregnated with asphalt and coated with cate Hydroxide); weather resistant mineral granules. 0033 Cookeite (Lithium Aluminum Silicate 0019. To provide a roofing shingle 1 which does not stick Hydroxide); to its neighboring shingles in a Stack, especially when the 0034 Nimite (Nickel Magnesium Iron Aluminum Stack is disposed on a pallet, a coating of a release material Silicate Hydroxide); 100 is placed on the bottom surface of the shingle 1, as depicted in FIG. 2, and the shingles 1 are bundled so that the 0035 Pennantite (Manganese Aluminum Silicate top Surface of each Shingle is adjacent the bottom Surface of Hydroxide); its neighboring shingle. The release coating comprises a continuous film of Solid particles having poor interlaminar 0036 Penninite (Iron Magnesium Aluminum Sili Strength when applied as a slurry coating. cate Hydroxide); 0037 Sudoite (Magnesium Aluminum Iron Silicate 0020 Particles that result in a film with poor interlaminar Hydroxide); Strength have good to excellent basal cleavage.
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