Roofing Shingles and Palleted Pluralities Thereof

This Application is a continuation of U.S. patent application Ser. No. 17/300,934, entitled “ROOFING SHINGLES AND PALLETED PLURALITIES THEREOF,” by Rakshith SRINIVASA et al., filed Dec. 15, 2021, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/125,895, entitled “ROOFING SHINGLES AND PALLETED PLURALITIES THEREOF,” by Rakshith SRINIVASA et al., filed Dec. 15, 2020 and Provisional Patent Application No. 63/125,897, entitled “ROOFING SHINGLES AND PALLETED PLURALITIES THEREOF,” by Rakshith SRINIVASA et al., filed Dec. 15, 2020, of which all are assigned to the current assignee hereof and incorporated herein by reference in their entireties.

The present disclosure relates to roofing shingles, for example, bituminous roofing shingles suitable for covering and protecting the roofs of houses, buildings, and other structures.

Roofing shingles, such as asphalt shingles, are applied in courses over a roof to protect the roof structure from weather, particularly water. Most roofing shingles are secured to an underlying structure using nails. Typically, the roofing shingles are designed to have a designated area, a so-called “nailing zone,” where the nails penetrate through the shingle to the underlying structure. In typical circumstances, nails that extend through the designated nail zone and to a sufficient depth in the roof structure will provide a secure and watertight roof.

Roofing shingles are typically based on bituminous materials, disposed on both sides of a substrate such as a fiberglass mesh or a felt material. The bituminous materials are typically coated with roofing granules in order to provide a less sticky surface and in order to protect the bituminous material from solar radiation.

In order to provide improved impact resistance to a roofing shingle, it is common to use a polymer-modified asphalt as the bituminous material. Modification with an elastomer such as a styrene-butadiene-styrene rubber is one common method to improve impact resistance.

However, the present inventors have noted that a drawback to some such materials is that shingles using them can suffer from deformation or sticking when stacked on a pallet and shipped. Accordingly, the present inventors have noted that, while it is common to provide a double “stack” of palleted asphalt shingles (i.e., one loaded pallet on top of another) for shipping, it is often necessary to limit palleted impact-resistant shingles to only a single stack (i.e., without stacking pallets on top of one another). This undesirable increases shipping costs.

Accordingly, the present inventors have determined that there is a need for improvements in roofing shingles and packaging thereof, especially with respect to impact-resistant roofing shingles.

The present inventors have determined a number of ways to reduce the problem of sticking and deformation when bituminous roofing shingles are stacked and shipped, especially for impact-resistant shingles. For example, the present inventors have determined that using small particulate material as a top surfacing in a zone where an overlay sheet overlaps an underlay sheet can help reducing so-called “humping” in that zone by providing a relatively lower apparent thickness of the overlay sheet in that zone of overlap as compared to a neighboring zone. Reducing humping in turn can help reduce buildup of pressure on such humps, thereby reducing the amount of sticking and deformation. The present inventors have also found that the mass of the shingle can be advantageously reduced, for example, by providing a relatively low weight of asphalt material in the bottom asphalt layer of each sheet, without a detriment in shingle performance. Reduced weight can advantageously cause less pressure to build through the stack. The present inventors have also found that the structure of the pallet on which the roofing shingles are stacked can be designed to help reduce sticking and deformation of stacked shingles, for example by providing a reduced amount of space between boards forming the top surface of the pallet, by having the plurality of top boards take up a high fraction of the occluded area of the top surface of the pallet and/or by providing relatively thick boards as the boards forming the top surface of the pallet. These can provide better and more support for the shingles, and thus cause less hotspots of high pressure and thus reduce deformation and sticking. These advances can be used singly and multiply in any combination.

Thus, in one aspect the disclosure provides a roofing shingle having an upper edge, a lower edge, a first end, and a second end, the roofing shingle comprising:

In another aspect, the disclosure provides a roofing system comprising:

In another aspect, the disclosure provides a method of installing a roofing system according to the disclosure, the method comprising:

In another aspect, the disclosure provides a palleted plurality of roofing shingles comprising a plurality of roofing shingles disposed in one or more stacks on a pallet, wherein the pallet has a top surface formed of a plurality of top boards, and wherein

Additional aspects of the disclosure will be evident from the disclosure herein.

As described above, the present inventors have noted that bituminous shingles, and especially impact-resistant shingles, e.g., based on elastomer-modified asphalt materials, can suffer from problems with sticking and deformation when they are stacked onto pallets and shipped. The present inventors have noted a number of advances, both in shingle design and in pallet design, that can be used singly or in any combination to improve the problems with sticking and deformation.

Accordingly, one embodiment of the disclosure is shown in top view in schematic top view in. Roofing shingleincludes an upper edge, a lower edge, a first endand a second end. Further, roofing shinglehas a headlap sectionextending from the upper edge of the shingle toward the lower edge; and an exposure sectionbelow headlap section, extending from a lower edge of the headlap section to the lower edge of the shingle. As is conventional, upon installation the headlap sectionmay be covered by one or more additional roofing shingles that are part of overlying course of shingles disposed on top of roofing shingle, while the exposure zoneremains exposed. A nailing zoneextends through headlap sectionacross the width of roofing shinglefrom first endto second end. Nailing zoneextends across the roofing shingle from the first end to the second end within the headlap section. As is conventional, the nailing zone is a portion of the roofing shingle that is suitable for receiving nails or other mechanical fasteners for securing roofing shingleto an underlying roof structure. In some embodiments, the nailing zone runs continuously from one end of the roofing shingle to the other, such as nail zone. In other embodiments, the nailing zone is formed by intermittent sections where fasteners are intended to be placed.

Roofing shingles as described herein are formed of an overlay sheet having a top surface and a bottom surface, and an underlay sheet having a top surface and a bottom surface. The overlay sheet overlaps the underlay sheet along an overlap zone extending from the first end to the second end of the roofing shingle, in or adjacent the nailing zone. The top surface of the underlay sheet is affixed to the bottom surface of the overlay sheet in the overlap zone.is a cross-sectional view of roofing shingleof, along the line A-A′. Here, overlay sheethas a top surface and a bottom surface, and underlay sheethas a top surfaceand a bottom surface. The overlay sheetoverlaps underlay sheetin an overlap zone. This overlap zone extends from the first end to the second end of the roofing shingle, in or adjacent to the nailing zone. In the embodiment of, the overlap zone is partially in the nailing zone and partially outside of the nailing zone. The top surfaceof the underlay sheetis affixed to the bottom surfaceof the overlay sheet in the overlap zone. The sheets can be affixed to one another in a variety of ways. For example, in certain embodiments an adhesive secures the top surface of the underlay sheet to the bottom surface of the overlay sheet. In other embodiments the sheets are attached to one another by another method, such as using a molten material, using mechanical fasteners, or deforming the layers of the shingle together, such as a stitching process. Various methods of securing sheets of a multilayer shingle together are described, for example, in U.S. Pat. Nos. 8,006,457, 8,316,608, 8,240,100, and 8,984,835.

In certain embodiments, the overlay sheet includes one or more tabs that are disposed on the underlay sheet and extend toward the lower edge of the shingle. This is shown in the schematic view of. Here, overlay sheetincludes tabs—here, so-called “dragon's teeth”—disposed on the underlay sheetand extending toward the lower edgeof the shingle.is a schematic cross-sectional view of roofing shingleof, along the line B-B′. Here, tabextends beyond the overlap zone and onto the underlay sheet. Various different geometric configurations of the tabs of the top shingle and the sheet layer are possible. Examples of such configurations are described, for example, in U.S. Pat. Nos. 6,715,252, 10,180,002, 10,180,003, 10,174,504, and U.S. Patent Publication No. 2017/0284100.

Each of the overlay sheet and the underlay sheet can be provided in conventional manners in the bituminous roofing art. For example, in various embodiments as otherwise described herein, each of the overlay sheet and underlay sheet includes a substrate, a top asphalt layer extending from a top surface of the substrate and being surfaced with one or more top surfacings, and a bottom asphalt layer extending from a bottom surface of the substrate and being surfaced with one or more bottom surfacings. A variety of substrates can be used. For example, in certain embodiments the substrate is a fibrous mat, for example, formed from woven or non-woven glass fibers, polymeric fibers, or a combination of glass and polymeric fibers, e.g., a fiberglass sheet or a roofing felt. The top and bottom asphalt layers can be made from the same material as one another, or from different materials. Asphalt materials used in bituminous shingles are well-known in the art. A conventional material is formed from a mixture of an asphalt (e.g., oxidized asphalt) and a filler (e.g., particulate limestone). The amount of filler can range, in some examples, from 40-70 wt % of the overall asphalt material. Particular asphalt materials useful in certain embodiments of the disclosure are described in more detail below. Asphalt material (e.g., the same as the material of the top asphalt layer and/or the material of the bottom asphalt layer) can penetrate into the substrate, e.g., into interstices within fibers of a fibrous substrate. In many examples, a single asphalt material is disposed throughout the substrate and forms the top and bottom layers of asphalt. One example of such a sheet is shown in partial schematic cross-sectional view in. Here, the sheetincludes a substrate(e.g., a fiberglass mesh), a top asphalt layerextending from a top surface of the substrate, and a bottom asphalt laterextending from a bottom surface of the substrate. In this embodiment, the substrate is impregnated with asphalt from the top asphalt layer.

As is conventional, each of the overlay sheet and the underlay sheet is surfaced with one or more surfacings. Such surfacings are well-known in the art, and typically take the form of particulate materials that are embedded in the softened asphalt materials while they are still warm. Surfacings typically help keep the asphalt materials from sticking as they warm up on a roof. Moreover, surfacings in the exposure zone of a shingle can protect the asphalt material of the top asphalt layer from being degraded by sunlight.

Top layer surfacings that are exposed in the exposure zone of a shingle are typically formed of roofing granules. Roofing granules can provide color to the exposed top surface of the roofing shingle in addition to protecting the asphalt material. For example, in some embodiments the roofing granules are highly reflective to reduce the temperature of the roofing shingles. In other embodiments, the roofing granules include algae resistance to prevent growth on the roofing shingles. The roofing granules can have a range of different material constructions, as will be appreciated by those of ordinary skill in the art. In some embodiments, the roofing granules include a base particle having at least one coating layer disposed thereon. In some embodiments, the base particles include chemically inert materials, such as inert mineral particles, solid or hollow glass or ceramic spheres, or foamed glass or ceramic particles. In some embodiments the base particles are inert mineral particles that are produced by a series of quarrying, crushing, and screening operations, and are generally intermediate between sand and gravel in size (that is, between about #8 US mesh and #70 US mesh). In some embodiments, the base particles have an average particle size of from about 0.1 mm to about 5 mm, e.g., from about 0.2 mm to 2.5 mm, e.g., from about 0.4 mm to about 2.4 mm. Further, in some embodiments, the base particles of the roofing granules include naturally occurring materials such as talc, slag, granite, silica sand, greenstone, andesite, porphyry, marble, syenite, rhyolite, diabase, greystone, quartz, slate, trap rock, basalt, and marine shells, as well as recycled manufactured materials such as crushed bricks, concrete, porcelain, fire clay, and the like. Crushed slate particles can also be used to form granules of a more or less flat morphology. In some embodiments the granules are synthetic granules, having synthetic base materials, such as those made of clays or other preceramic materials. In some embodiments the base particles of the roofing granules are formed as solid or hollow glass spheres in a similar range of sizes. In some embodiments, the glass spheres are coated with a suitable coupling agent to provide improved adhesion to a binder included in a coating that surrounds the base particle. Applicable synthetic roofing granules and methods of manufacturing them are described in U.S. Pat. Nos. 7,811,630, 8,668,954, 8,722,140, 9,422,719, 10,094,115, U.S. Patent Publication No. 2018/0186694, U.S. Patent Publication No. 2018/0194684, U.S. Patent Publication No. 2019/0300449, and U.S. Patent Publication No. 2019/0323240. As will be understood by those of ordinary skill in the art, the color of the roofing granules may be imparted, for example, by coloring pigments that are included in the granules, such as in a binder of a coating on the base particle. Such pigments may include suitable metal oxides.

Top layer surfacings that are not exposed in an exposure zone of a shingle, e.g., in the headlap zone and surfacings of an underlay sheet that are covered by an overlay sheet, can be provided by a variety of particulate materials. For manufacturing efficiency, it may be desirable to simply surface these top surface regions with the same roofing granules as in the exposure zone. But other, cheaper granules may be used. These can be, e.g., so-called “granule fines,” i.e., small particulate waste from the manufacture of conventional granules, or can be uncoated versions of the granules described above (e.g., just the base particles described above). Sand can also be used, as can other particulate materials such as mica flakes, copper slag, coal slag, sand, talc, expanded clay, slate flour, powdered limestone and silica dust. Any combination can be used. Bottom layer surfacings are typically the same as described above with respect to the cheaper materials for use in unexposed areas.

In the embodiment of, the surfacing of the top asphalt layeris roofing granules; and the surfacing of the bottom asphalt layer is sand.

As noted above, the present inventors have made a number advances in addressing the problem of roofing single and deformation, especially with respect to impact-resistant roofing shingles as described below. These advances can be used singly and multiply in any combination.

For example, in certain embodiments as otherwise described herein, a bottom portion of each of the overlay sheet and the underlay sheet comprising the bottom asphalt layer and the one or more bottom surfacings has a weight of no more than 11 pounds per 100 square feet. The weight of the bottom portion can be determined by physically scraping the asphalt layer and the bottom surfacing(s) from an area of the substrate of a sheet, then weighing the scraped material and dividing by area and normalizing to 100 square feet. The present inventors have found that acceptable shingle quality can be provided even when lower weights of materials, especially of asphalt material, are used in the bottom portions of the sheets. This is true even when the asphalt material is an impact-resistant elastomer-modified asphalt material. In certain embodiments as otherwise described herein, the bottom portion of each of the overlay sheet and the underlay sheet comprising the bottom asphalt layer and the one or more bottom surfacings has a weight of no more than 10.7 pounds per 100 square feet, e.g., no more than 10.5 pounds per 100 square feet. For example, in various embodiments as otherwise described herein, the weight of the bottom portion of each of the overlay sheet and the underlay sheet is in the range of 9-11 pounds per 100 square feet, e.g., in the range of 9-10.7 pounds per 100 square feet, or 9-10.5 pounds per 100 square feet, or 9.5-11 pounds per 100 square feet, or 9.5-10.7 pounds per 100 square feet, or 9-10.5 pounds per 100 square feet. In other embodiments as otherwise described herein, the weight of the bottom portion of each of the overlay sheet and the underlay sheet is in the range of 10-11 pounds per 100 square feet, e.g., in the range of 10-10.7 pounds per 100 square feet, or 10-10.5 pounds per 100 square feet, or 10.3-11 pounds per 100 square feet, or 10.3-10.7 pounds per 100 square feet, or 10.3-10.5 pounds per 100 square feet.

In certain embodiments as otherwise described herein (e.g., in combination with the reduced weights described above, or independently of asphalt coating weight), the shingle has at its top surface a small particulate zone defined by a top surfacing of a small particulate material extending from the first end to the second end of the roofing shingle, the small particulate material having a d50 particle size of no more than half a d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone, the small particulate zone being at least one inch in height as measured in a direction from the upper edge to the lower edge of the shingle, the small particulate zone at least partially overlapping the overlap zone (i.e., of the overlay sheet and the underlay sheet).

The present inventors have noted that a particular point of failure of shingles during shipment and storage is in the region of the overlap zone. Without intending to be bound by theory, the inventors note the overlap of the two layers can cause a hump in the shingle, which can be especially notable in regions where there is a relatively narrow hump, e.g., in the overlap region described with respect toabove. Such a narrow hump can result in a relatively high local pressure from overlying shingles in a packaged stack. In contrast, local pressure buildup can be substantially less in regions where a tab is provided, as described with respect to, as there is more surface area to support overlying shingles in the stack. In certain embodiments as otherwise described herein, the roofing shingle includes one or more areas where the overlay sheet is disposed on the underlay sheet with a degree of overlap of no more than 1.5 inches, e.g., no more than 1 inch, for example, in the range of 0.3-1.5 inches, or 0.3-1 inch, or 0.5-1.5 inches, or 0.5-1 inch, or 0.75-1.5 inches. The overlap of the sheets at the line A-A′ of, as shown in, has such a geometry, while the overlap of the sheets at the line B-B′ does not.

The present inventors have found that use of a small particulate material overlapping at least part of the overlap zone can lower the apparent thickness of the shingle in the overlap zone, and thus can reduce the apparent hump in the packaged shingles.

One embodiment of such a roofing shingle is shown in schematic top view in. Here, roofing shingleincludes an overlay sheetand an underlay sheet, with tabsof the overlay sheet extending toward the lower edge of the shingle on top of the underlay sheet, substantially as described above. The overlap zoneis defined by the minimum extent of overlap of the overlay and underlay sheets across the shingle. This shingle has at its top surface, here, on the top surface of the overlay sheet, a small particulate zonedefined by a top surfacing of a small particulate material extending from the first end to the second end of the roofing shingle. The small particulate material has a d50 particle size of no more than half a d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone. The lower adjacent zone is the granule-coated surface that borders the small particulate zone toward the lower edge of the roofing shingle—here, indicated by reference number. The small particulate zone is at least one inch in height as measured in a direction from the upper edge to the lower edge of the shingle. Notably, the small particulate zoneat least partially overlaps the overlap zone; here, the overlap is partial, but not complete; the small particulate zone does not extend into the portionof the overlap zone. However, in other embodiments contemplated herein, the small particulate zone completely overlaps the overlap zone.

As used herein, the d50 particle size is the median particle size, i.e., the size of the particle at which 50% of the particles are of larger particle size and 50% are of smaller particle size. As used herein, “particle size” is the largest dimension of the particle.

The person of ordinary skill in the art will appreciate that a variety of materials can be used as the small particulate material. For example, in certain desirable embodiments as otherwise described herein, the small particulate material is sand. In various embodiments as otherwise described herein, the small particulate material is mica flakes, copper slag, coal slag, sand, talc, expanded clay, slate flour, powdered limestone or silica dust. Of course, a variety of other materials, such as those described above with respect to the roofing granules and base particles therefor, can be used at the small particulate material when provided at an appropriate particle size.

The small particulate material can advantageously be provided in a variety of particle sizes with respect to the roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone. For example, in certain embodiments as otherwise described herein, the small particulate material having a d50 particle size of no more than ⅓ of (e.g., no more than ¼ of, or no more than ⅕ of) a d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone. By providing a larger difference between the particle sizes, more of a “hump” formed by the overlapping sheets can be compensated for. In various embodiments, the d50 particle size of the small particulate material is in the range of 1/10-½ of the d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone, e.g., 1/10-⅓, or 1/10-¼, or 1/10-⅕, or ⅛-⅓, or ⅛-¼, or ⅛-⅕, or ⅙-⅓, or ⅙-¼.

The d95 particle size can also be important, as if there are too many large particles in the small particulate material, they can undesirably raise the apparent top surface in the small particulate zone. Accordingly, in certain embodiments as otherwise described herein, the small particulate material has a d95 particle size of no more than ½ of (e.g., no more than ¼ of, or no more than ¼ of, or no more than ⅕ of) a d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone. In various embodiments, the d95 particle size of the small particulate material is in the range of 1/10-½ of the d50 particle size of roofing granules disposed as a top surfacing in a lower adjacent zone to the small particulate zone, e.g., 1/10-⅓, or 1/10-¼, or 1/10-⅕, or ⅛-⅓, or ⅛-¼, or ⅛-⅕, or ⅙-⅓, or ⅙-¼.

The particle size of the small particulate material can vary, e.g., depending on the particle size of the roofing granules in the lower adjacent zone. For example, in certain embodiments as otherwise described herein, the small particulate material has a d50 particle size (and optionally a d95 particle size) of no more than 250 microns, e.g., no more than 200 microns, or no more than 150 microns, for example, in the range of 10-250 microns, e.g., 10-200 microns, or 10-150 microns or 25-250 microns, or 25-200 microns, or 25-150 microns, or 50-250 microns, or 50-200 microns. In certain embodiments as otherwise described herein, the small particulate material has a d50 particle size (and optionally a d95 particle size) of no more than 350 microns, e.g., no more than 300 microns, for example, in the range of 10-350 microns, e.g., 10-300 microns, or 25-350 microns, or 25-300 microns, or 50-350 microns, or 50-300 microns, or 100-350 microns, or 100-300 microns.

In certain embodiments as otherwise described herein, the small particulate material has a d50 particle size (and optionally a d95 particle size) of no more than 100 microns, e.g., no more than 80 microns, or no more than 60 microns, for example, in the range of 10-100 microns, e.g., 10-80 microns, or 10-60 microns or 25-100 microns, or 25-80 microns, or 25-60 microns.

The size of the roofing granules in the lower adjacent can also vary. For example, in certain embodiments as otherwise described herein, the roofing granules in the lower adjacent zone have a d50 of at least 300 microns, e.g., at least 350 microns, for example, in the range of 300-2000 microns, e.g., or 300-1500 microns, or 300-1000 microns, or 350-2000 microns, or 350-1500 microns, or 350-1000 microns. In certain embodiments as otherwise described herein, the roofing granules in the lower adjacent zone have a d50 of at least 400 microns, e.g., at least 450 microns, for example, in the range of 400-2000 microns, e.g., 400-1500 microns, or 400-1000 microns, or 450-2000 microns, or 450-1500 microns, or 450-1000 microns.

Notably, in desirable embodiments, a top surface of the surfacing in the small particulate zone can be recessed from a top surface of the roofing granules in the lower adjacent zone. For example, in certain embodiments, a top surface of the surfacing in the small particulate zone is recessed from a top surface of the roofing granules in the lower adjacent zone by at least 400 microns, e.g., at least 500 microns or at least 700 microns, for example, in the range of 400-1500 microns, or 400-1200 microns, or 400-1000 microns, or 500-1500 microns, or 500-1200 microns, or 500-1000 microns, or 700-1500 microns, or 700-1200 microns.

As described above, in some cases, the overlap of the small particulate zone and the overlap zone is partial, but not complete. For example, in the embodiment of, the small particulate zonedoes not extend into the portionof the overlap zone. In such embodiments, the remaining portion of the overlap zone that is surfaced with roofing granules (in, portion) can remain as a high-pressure area when the shingles are stacked. The present inventors note, however, that in many cases it can be desirable to retain such a portion of the overlap zone surfaced with roofing granules, in order to provide for flexibility in installation of the roofing shingle. To overcome this, the present inventors have determined that shingles can be stacked when packaged for shipping so that top surfaces of shingles can face one another in pairs. The shingles can be rotated 180 degrees relative to one another, and the portion of the overlap zone surfaced with roofing granules of a first shingle can be disposed against the small particulate zone of a second, facing shingle. In this way, the portion of the overlap zone surfaced with roofing granules of the first shingle can fit into the recess formed by the small particulate zone of the second shingle and be more protected from deformation.

The present inventors have noted that issues with sticking and deformation during shipment are especially acute with certain polymer-modified asphalt materials, such as elastomer-modified materials. Accordingly, in certain embodiments as otherwise described herein, in each of the overlay sheet and the underlay sheet, the top asphalt layer is formed of a polymer-modified asphalt material, e.g., an elastomer-modified asphalt material. For example, in certain such embodiments, the top asphalt layers are formed of an SBS-modified asphalt material, e.g., with a weight ratio of asphalt to SBS in the range 5-26, or 10-26. As the person of ordinary skill in the art would appreciate, SBS is a styrene/butadiene/styrene elastomer. Such materials can be highly impact resistant, which is advantageous in a roofing shingle. However, it can provide the shingle with a lowered resistance to pressure over time.

The person of ordinary skill in the art will appreciate that a variety of formulations of SBS-modified asphalt material can be used. In certain embodiments, the asphalt material includes SBS (e.g., in the range of 0.5-5 wt %, such as about 1.8 wt %); an unoxidized asphalt (e.g., in the range of 10-30 wt %, such as about 15.6 wt %), an oxidized asphalt (e.g., in the range of 10-30 wt %, such as about 17.5 wt %); and an inorganic filler (for example, limestone, e.g., in the range of 50-75 wt %, about 65.0 wt %). The unoxidized asphalt is typically first mixed with the SBS polymer, then the mixture is combined with the oxidized asphalt, as the viscosity of the mixture is too high when the SBS polymer is mixed into oxidized asphalt alone.

The present inventors note that the unoxidized asphalt is softer than the oxidized asphalt, and thus the mixed asphalt component of these materials is softer than the oxidized asphalt used in conventional shingles. For example, in certain embodiments, the asphalt component (i.e. including all bituminous materials in combination) of the asphalt material of the top layer of each of the overlay sheet and underlay sheet has a softening point of no more than 180° F., e.g., no more than 160° F., for example, in the range of 120-180° F., e.g., 120-160° F., or 130-180° F., or 130-160° F. This is in contrast to an oxidized asphalt typically used in bituminous shingles, which has a softening point of about 210° F. Softening points can be determined by ASTM D36. In certain embodiments, the asphalt component of the asphalt material of the top layer of each of the overlay sheet and underlay sheet has a penetration at 77° F. of at least 35 dmm (deci-millimeters), e.g., at least 50 dmm, for example, 35-85 dmm, e.g., 35-70 dmm, or 50-85 dmm, or 50-70 dmm. This is in contrast to an oxidized asphalt typically used in bituminous shingles, which has a penetration of 20 dmm. Penetration can be determined according to ASTM D5. Without intending to be bound by theory, the present inventors surmise that under pressure, the network of elastomeric polymer (e.g., SBS) in the overall material can deform, allowing the relatively soft asphalt component to be squeezed out of the elastomeric polymer matrix. The present inventors have noted that shingles based on these materials are especially susceptible to sticking and deformation, and as such that shingles based on these materials are especially advantaged when configured as described herein.

As described above, in some cases the asphalt material of the bottom asphalt layers of the overlay sheet and the underlay sheet can be different from the materials of their top layers. However, in certain desirable embodiments, the materials are similar, or even the same. Accordingly, in certain embodiments as otherwise described herein, in each of the overlay sheet and the underlay sheet, the bottom asphalt layer is formed of a polymer-modified asphalt, e.g., an elastomer-modified asphalt. In certain embodiments as otherwise described herein, in each of the overlay sheet and the underlay sheet the bottom asphalt layer is formed of SBS-modified asphalt, e.g., having a ratio of SBS to asphalt in the range of 5-26, or 10-26. Similarly, the asphalt component of the asphalt material of the top layer of each of the overlay sheet and underlay sheet has a softening point and/or a penetration value as described above.

Conventional shingle sheet constructions can be used to provide the overlay sheet and the underlay sheet. For example, in certain embodiments as otherwise described herein, in each of the overlay sheet and the underlay sheet, the substrate is a fibrous mat (e.g., a fiberglass mat or a roofing felt) that is saturated with one of the asphalt materials of the top asphalt layer and the bottom asphalt layer.

As is conventional, the shingle can include a nailing zone extending across the roofing shingle from the first end to the second end within the headlap section. The nailing zone is a zone that is suitable for fastening of the shingle to a roof surface. The nailing zone can be visually delineated at a top surface of the roofing shingle, e.g., by lines of paint. In the embodiment of, the nailing zone is indicated by reference number. The small particulate zone can, for example, overlap with the nailing zone. Further, in certain embodiments, the small particulate zone extends beyond the nailing zone. For example in the embodiment of, small particulate zoneextends beyond nailing zone.

In certain embodiments of the roofing shingle as otherwise described herein, the width of the roofing shingle is at least 24 inches, e.g., at least 30 inches, e.g., at least 42 inches. Further, in some embodiments, the width of the roofing shingle is no more than 48 inches, e.g., no more than 42 inches, e.g., no more than 40 inches. For example, in some embodiments, the width of the roofing shingle is in a range between 24 and 48 inches, e.g., in a range between 30 and 42 inches, e.g., in a range between 36 and 40 inches, e.g., 38-¾ inches, or 39.4 inches (i.e., 1 m).

Further, in certain embodiments of the roofing shingle as otherwise described herein, the height of the headlap area is at least 4 inches, e.g., at least 6 inches, e.g., at least 7.25 inches. Further, in some embodiments, the height of the headlap area is no more than 14 inches, e.g., no more than 10 inches, e.g., no more than 7.75 inches. For example, in some embodiments, the height of the headlap area is in a range between 4 inches and 14 inches, e.g., in a range between 6 and 10 inches, e.g., in a range between 7.25 inches and 7.75 inches, e.g., 7⅝ inches. Likewise, in certain embodiments of the roofing shingle as otherwise described herein, the height of the exposed area is at least 4 inches. Further, in some embodiments, the height of the exposed area is no more than 12 inches. For example, in some embodiments, the height of the exposed area is in a range between 4 and 12 inches, e.g.,, inches, 6 inches, 7 inches, 7.5 inches, 8 inches or 10 inches. Further, in certain embodiments the height of the exposed area is in a range between 5¼ inches and 5¾ inches, e.g., 5⅝ inches.

Another aspect of the disclosure is a roofing system that includes a roof structure, a first roofing shingle according to the disclosure disposed on the roof structure, and a first mechanical fastener securing the first roofing shingle to the roof structure. The first mechanical fastener is disposed within the nailing zone and passes through the overlay sheet. In some embodiments, the first mechanical fastener is one of a plurality of mechanical fasteners that secure the first roofing shingle to the roof structure. Various types of mechanical fasteners may be used to secure the first roofing shingle to the roof structure, including nails, staples, screws, or others.

In certain embodiments of the roofing system as otherwise described herein, the roof structure includes a frame and sheathing disposed over the frame. For example, the frame may be composed of frame elements such as rafters that support the sheathing. Further in some embodiments, the sheathing is continuous and forms a continuous surface over the frame elements. In other embodiments, the sheathing includes spaced sections. For example, the sheathing may be formed of a series of planks with a gap therebetween.

In certain embodiments of the roofing system as otherwise described herein, a second roofing shingle is disposed on top of the first roofing shingle so as to cover a portion of the headlap section of the first roofing shingle while leaving the exposure section of the first roofing shingle uncovered. A second mechanical fastener secures the second roofing shingle to the roof structure. The second mechanical fastener is disposed within the nail zone of the second roofing shingle and passes through the overlay sheet of the second roofing shingle. In some embodiments, the second mechanical fastener is one of a plurality of mechanical fasteners that secure the second roofing shingle to the roof structure. The second roofing shingle is part of a second course of shingles that are disposed over a first course of shingles which includes the first roofing shingle.

Such a roofing system is shown in. Roofing systemincludes first roofing shingledisposed on a roof structure. A second roofing shingleis disposed on top of first roofing shingleso as to overlap with a majority of the headlap sectionbut leave exposure sectionuncovered. Further, the lateral position of second roofing shingleis staggered or offset with respect to first roofing shinglesuch that second roofing shinglecovers a majority but not all of the headlap sectionof first roofing shingle. A second mechanical fastener passes through the overlay sheetto secure the second roofing shingleto the roof structure. In some embodiments, the first and second roofing shingles are part of a finished roofing system where further roofing shingles cover the remaining areas of the roof structure. In such an embodiment another roofing shingle would cover the remaining exposure portion of the headlap section of the first shingle, and other roofing shingles would cover the headlap section of the second roofing shingle.

In certain embodiments of the roofing system as otherwise described herein, the second mechanical fastener also passes through the first roofing shingle. For example, in some embodiments, the headlap section of each of the roofing shingles is larger than the exposure section. Accordingly, when the second roofing shingle is position on top of the first roofing shingle so as to overlap the headlap section of the first roofing shingle but leave the exposure section uncovered, the upper end of the headlap section of the first roofing shingle overlaps with the lower end of the second roofing shingle. In particular, the nailing zone of the second roofing shingle overlaps with the upper end of the headlap section of the first shingle. Consequently, when a mechanical fastener is inserted through the nailing zone of the second roofing shingle, the mechanical fastener also passes through the first roofing shingle at the upper end of the headlap section. For example, in roofing system, as shown in, the second mechanical fastenerpasses through the second roofing shingleso as to secure the second roofing shingleto the roof structure. The second mechanical fastener also passes through the headlap sectionof first roofing shingle.