US007836654B2
`
`(12) United States Patent
`Belt et al.
`
`(lO) Patent No.:
`(45) Date of Patent:
`
`US 7,836,654 B2
`Nov. 23, 2010
`
`(54) SHINGLE WITH REINFORCED NAIL ZONE
`AND METHOD OF MANUFACTURING
`
`4,680,909 A
`
`7/1987 Stewart
`
`4,706,435 A
`
`11/1987 Stewart
`
`(75)
`
`Inventors: James S. Belt, Utica, OH (US); BertW.
`Elliott, Toledo, OH (US)
`
`(73) Assignee: Owens Coming Intellectual Capital,
`LLC, Toledo, OH (US)
`
`4,717,614 A *
`
`1/1988 Bondoc et al ............... 428/143
`
`4,755,545 A
`
`7/1988 Lalwani
`
`4,817,358 A
`
`4/1989 Lincoln et al.
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`(21) Appl. No.: 11/198,522
`
`(22) Filed:
`
`Aug. 5, 2005
`
`(65)
`
`Prior Publication Data
`
`US 2007/0042158 A1
`
`Feb. 22, 2007
`
`CA
`
`1207975
`
`7/1986
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`(51) Int. Cl.
`EO4D 1/00
`(2006.01)
`(52) U.S. CI ............................................ 521557; 52/527
`(58) Field of Classification Search ................... 52/314,
`52/315,554, 555, 557, 559
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`1,597,135 A
`1,601,731 A
`1,665,222 A
`1,701,926 A
`1,799,500 A
`2,161,440 A *
`2,798,006 A
`2,847,948 A
`3,252,257 A
`3,377,762 A
`3,468,086 A
`3,468,092 A
`3,624,975 A
`3,664,081 A
`4,459,157 A
`
`8/1926 Wittenberg
`10/1926 Flood
`4/1928 Robinson
`2/1929 Kirschbraun
`4/1931 Brophy
`6/1939 Venrick ....................... 52/555
`7/1957 Oldfieldet al.
`8/1958 Truitt
`5/1966 Price et al.
`4/1968 Chalmers
`9/1969 Warner
`9/1969 Chalmers
`12/1971 Morganetal.
`5/1972 Martin et al.
`7/1984 Koons
`
`Chinese Office Action for Chinese Application No. 200680028893.4,
`Mar. 27, 2009.
`
`(Continued)
`
`Primary Examine~Brian E Glessner
`Assistant Examiner Adriana Figueroa
`(74) Attorney, Agent, or Firm~acMillan, Sobanski &
`Todd, LLC
`
`(57)
`
`ABSTRACT
`
`A roofing shingle includes an asphalt-coated sheet having a
`tab portion normally exposed on a roof and a headlap portion
`normally covered-up on a roof. The headlap portion has a
`lower zone that extends longitudinally between a first end and
`a second end of the roofing shingle adjacent the tab portion,
`and an upper zone adjacent the lower zone. At least a portion
`of the asphalt-coated sheet has granules adhered thereto. A
`reinforcement member is ad3aered to the lower zone of the
`headlap portion.
`
`43 Claims, 3 Drawing Sheets
`
`FAST FELT 2015, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 7,836,654 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`4/1989 Algrim et al.
`4,824,880 A
`1/1993 Hannahetal.
`5,181,361 A
`5/1993 Hannah et al.
`5,209,802 A
`8/1993 Robinson ..................... 52/518
`5,239,802 A *
`6/1995 Stahl et al.
`5,426,902 A
`5,571,596 A * 11/1996 Johnson ...................... 428/143
`11/1996 Grabek, Jr.
`5,577,361 A
`8/1997 Stahletal.
`5,660,014 A
`5,822,943 A * 10/1998 Frankoskietal .............. 52/518
`5/1999 Stahletal.
`5,901,517 A
`6/1999 Roberts
`5,916,103 A
`9/1999 Stahl et al.
`5,950,387 A
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`6,021,611 A
`3/2000 Stahl et al.
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`7/2000 Chich
`6,083,592 A
`11/2000 Malarkeyetal.
`6,145,265 A
`11/2000 Nowacek et al.
`6,148,578 A
`3/2001 Hudson, Jr. et al.
`6,199,338 B1
`4/2001 Kingetal.
`6,220,329 B1
`2/2002 Geissels et al.
`6,343,447 B2
`3/2002 Becker et al ................ 156/260
`6,355,132 B1 *
`6/2002 Malarkey et al.
`6,397,546 B1
`6/2002 Karpinia .................... 52/748.1
`6,397,556 B1 *
`6,471,812 B1 * 10/2002 Thompson et al ........... 156/242
`6,487,828 B1 * 12/2002 Phillips ....................... 52/554
`6,523,316 B2 2/2003 Stahletal.
`8/2003 Aschenbeck
`6,610,147 B2
`
`1/2004 Becker et al.
`6,679,020 B2
`1/2004 Becker et al.
`6,679,308 B2
`3/2004 Kiik et al.
`6,708,456 B2
`3/2004 Miller et al ................. 442/148
`6,709,994 B2*
`7/2004 Kalkanoglu et al.
`6,758,019 B2
`6,804,919 B2* 10/2004 Railkar ........................ 52/105
`11/2004 Elliott et al.
`6,823,637 B2
`1/2006 Kiik et al.
`6,990,779 B2
`10/2006 Kalkanoglu et al.
`7,118,794 B2
`2001/0049002 A1
`12/2001 McCumber et al.
`2003/0040241 A1
`2/2003 Kiik et al.
`2003/0093963 A1
`5/2003 Stahl et al.
`2004/0055240 A1
`3/2004 Kiik et al.
`2004/0083673 A1
`5/2004 Kalkanoglu et al.
`2004/0083674 A1
`5/2004 Kalkanoglu et al.
`2004/0206035 A1
`10/2004 Kandalgaonkar
`2004/0258883 AI* 12/2004 Weaver ....................... 428/143
`2006/0032174 A1
`2/2006 Floyd
`
`FOREIGN PATENT DOCUMENTS
`
`CN
`
`2176391Y 9/1994
`
`OTHER PUBLICATIONS
`
`International Search Report PCT/US2007/007827 dated Aug. 29,
`2007.
`US Office Action dated Aug. 21, 2009, U.S. Appl. No. 11/396,498.
`US Office Action dated Mar. 18, 2010, U.S. Appl. No. 11/396,498.
`International Search Report PCT/US2006/030633 dated Nov. 21,
`2006.
`
`* cited by examiner
`
`FAST FELT 2015, pg. 2
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 23, 2010 Sheet 1 of 3
`
`US 7,836,654 B2
`
`FAST FELT 2015, pg. 3
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 23, 2010 Sheet 2 of 3
`
`US 7,836,654 B2
`
`:E
`
`FAST FELT 2015, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Nov. 23, 2010 Sheet 3 of 3
`
`US 7,836,654 B2
`
`-~IG. 3
`
`(PRIOR ART)
`
`92
`
`99-,~
`
`~ ,66 .H4 ,19 74-.~ H5. 6 ,//~,,~
`
`v.///; V///////?////////////////////~
`
`~68 "~--74 66
`
`’~///////////////////J\ 19J [X\\\\\\\\\\\\\\\\\\~?
`
`76A
`
`TIG. 4
`
`FAST FELT 2015, pg. 5
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`US 7,836,654 B2
`
`1
`SHINGLE WITH REINFORCED NAIL ZONE
`AND METHOD OF MANUFACTURING
`
`TECHNICAL FIELD
`
`This invention relates to a shingle, such as a roofing
`shingle, and in particular, to a roofing shingle having an
`improved nail zone.
`
`BACKGROUND OF THE INVENTION
`
`Asphalt-based roofing materials, such as roofing shingles,
`roll roofing and commercial roofing, are installed on the roofs
`of buildings to provide protection from the elements, and to
`give the roof an aesthetically pleasing look. Typically, the
`roofing material is constructed of a substrate such as a glass
`fiber mat or an organic felt, an asphalt coating on the sub-
`strate, and a surface layer of granules embedded in the asphalt
`coating.
`A common method for the manufacture of asphalt shingles
`is the production of a continuous sheet of asphalt material
`followed by a shingle cutting operation which cuts the mate-
`rial into individual shingles. In the production of asphalt sheet
`material, either a glass fiber mat or an organic felt mat is
`passed through a coater containing hot liquid asphalt to form
`a tacky, asphalt coated sheet. Subsequently, the hot asphalt
`coated sheet is passed beneath one or more granule applica-
`tors which discharge protective and decorative surface gran-
`ules onto portions of the asphalt sheet material.
`In certain types of shingles, it is especially desired that the
`shingles define a sufficiently wide area, often known in the
`industry as the "nail zone," in order to make installation of
`roofs using shingles, such as laminated shingles, more effi-
`cient and secure. One or more lines or other indicia painted or
`otherwise marked longitudinally on the surface of the shingle
`may define such a nail zone. It is especially desired that the
`shingles define a nail zone that allows the installers to have
`some latitude in the nail placement.
`Additionally, the leading edge of some shingles may expe-
`rience lift offin high wind situations. Therefore, there is also
`a need for shingles where the shingles have a sufficiently high
`nail pull-through value so that the installed shingles have
`improved performance in high wind situations.
`
`SUMMARY OF THE INVENTION
`
`The above objects as well as other objects not specifically
`enumerated are achieved by a roofing shingle including an
`asphalt-coated sheet having a tab portion normally exposed
`on a roof and a headlap portion normally covered-up on a
`roof. The headlap portion has a lower zone that extends lon-
`gitudinally between a first end and a second end of the roofing
`shingle adjacent the tab portion, and an upper zone adjacent
`the lower zone. At least a portion of the asphalt-coated sheet
`has granules adhered thereto. A reinforcement member is
`adhered to the lower zone of the headlap portion.
`A second embodiment of the invention the roofing shingle
`is a laminated roofing shingle including an underlay member
`and an overlay member attached to the underlay member. The
`overlay member has a tab portion normally exposed on a roof
`and a headlap portion normally covered-up on a roof, and the
`headlap portion has a lower zone adjacent the tab portion and
`an upper zone adjacent the lower zone, wherein at least a
`portion of the overlay member has granules adhered thereto.
`The overlay member has a first height and the underlay mem-
`ber has a second height, the second height being one of less
`than one-half the first height and equal to one-half the first
`
`2
`height, the overlay member and the underlay member thereby
`defining a two layer portion and a single layer portion of the
`laminated shingle. At least a portion of the reinforcement
`member is adhered to the single layer portion of the laminated
`5 shingle.
`
`A third embodiment of the invention is method of making
`a laminated shingle including coating a shingle mat with
`roofing asphalt to make an asphalt-coated sheet; adhering a
`reinforcement member to a portion of the asphalt-coated
`10 sheet; and covering the asphalt-coated sheet, and optionally
`
`covering the reinforcement member, with granules to make a
`granule-covered sheet. The granule-covered sheet is divided
`into an overlay sheet and an underlay sheet, wherein the
`overlay sheet has a tab portion normally exposed on a roof and
`15 a headlap portion normally covered-up on a roof, and the
`
`headlap portion has a lower zone adjacent the tab portion and
`an upper zone adjacent the lower zone. The reinforcement
`member is adhered to the lower zone of the headlap portion,
`and the overlay sheet is laminated to the underlay sheet to
`2o make the laminated shingle.
`
`25
`
`30
`
`35
`
`A fourth embodiment of the invention is a method of mak-
`ing a laminated shingle including coating a shingle mat with
`roofing asphalt to make an asphalt-coated sheet; covering the
`asphalt-coated sheet with granules to make a granule-covered
`sheet; and adhering a reinforcement member to a portion of
`the granule-covered sheet. The granule-covered sheet is
`divided into an overlay sheet and an underlay sheet, wherein
`the overlay sheet has a tab portion normally exposed on a roof
`and a headlap portion normally covered-up on a roof. The
`headlap portion has a lower zone adjacent the tab portion and
`an upper zone adjacent the lower zone. The reinforcement
`member is adhered to the lower zone of the headlap portion,
`and the overlay sheet is laminated to the underlay sheet to
`make the laminated shingle.
`
`A fifth embodiment of the invention is bundle of laminated
`roofing shingles stacked such that every other of the shingles
`is at least one of inverted and turned 180 degrees relative to an
`adjacent one of the shingles. The shingles have an overlay
`
`4o laminated with an underlay. The overlay has a tab portion
`with cutouts normally exposed on a roof and a headlap por-
`tion normally covered-up on a roof, and the headlap portion
`has a lower zone adjacent the tab portion and an upper zone
`adjacent the lower zone. The lower zone has substantially no
`
`45 granules adhered thereto. The bundle defines a central area
`that substantially encompasses the lower zones of the stacked
`shingles. The laminated roofing shingles are double-layered,
`wherein the lack of granules in the lower zones of the stacked
`shingles results in the central area of the bundle having a
`5o height substantially identical to a height of a remainder of the
`bundle outside of the central area.
`
`A sixth embodiment of the invention is a method of reduc-
`ing humping of a bundle of stacked laminated roofing
`shingles. The shingles have an overlay laminated with an
`55 underlay. The overlay has a tab portion with cutouts normally
`exposed on a roof and a headlap portion normally covered-up
`on a roof. The headlap portion has a lower zone adjacent the
`tab portion and an upper zone adjacent the lower zone. The
`method includes providing the lower zone of the headlap
`6o portion having substantially no granules adhered thereto. The
`shingles are stacked such that every other of the shingles is at
`least one of inverted and turned 180 degrees relative to an
`adjacent one of the shingles, thereby defining a bundle of
`stacked laminated roofing shingles. The bundle defines a
`65 central area that substantially encompasses the lower zones.
`The laminated roofing shingles are double-layered, and the
`lack of granules in the lower zones of the stacked shingles
`
`FAST FELT 2015, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 7,836,654 B2
`
`3
`results in the central area of the bundle having a height sub-
`stantially identical to a height of a remainder of the bundle
`outside the central area.
`Various objects and advantages of this invention will
`become apparent to those skilled in the art from the following
`detailed description of the various embodiments, when read
`in light of the accompanying drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a schematic elevational view of an apparatus for
`making shingles according to the invention.
`FIG. 2 is a perspective view of a laminated shingle having
`a reinforcement member in accordance with this invention.
`FIG. 3 is a schematic sectional view of a pair of laminated
`roofing shingles of the prior art stacked together, shown in
`exaggerated thickness to illustrate humping of the stacked
`shingles.
`FIG. 4 is a schematic sectional view of a pair of laminated
`roofing shingles according to the invention stacked together,
`shown in exaggerated thickness to illustrate how the rein-
`forcement members of adjacent shingles cooperate to reduce
`humping of the stacked shingles.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`Referring now to the dxawings, there is shown in FIG. 1 an
`apparatus 10 for manufacturing an asphalt-based roofing
`material according to the invention. In the illustrated embodi-
`ment, the manufacturing process involves passing a continu-
`ous sheet 12 in a machine direction (indicated by the arrows)
`through a series of manufacturing operations. The sheet usu-
`ally moves at a speed of at least about 200 feet/minute (61
`meters/minute), and typically at a speed within the range of
`between about 450 feet/minute (137 meters/minute) and
`about 800 feet/minute (244 meters/minute). The sheet, how-
`ever, may move at any desired speed.
`In a first step of the illustrated manufacturing process, a
`continuous sheet of substrate or shingle mat 12 is payed out
`from a roll 14. The substrate can be any type known for use in
`reinforcing asphalt-based roofing materials, such as a non-
`woven web of glass fibers. The shingle mat 12 may be fed
`through a coater 16 where an asphalt coating is applied to the
`mat 12. The asphalt coating can be applied in any suitable
`manner. In the illustrated embodiment, the mat 12 contacts a
`roller 17, which is in contact with a supply of hot, melted
`asphalt. The roller 17 completely covers the mat 12 with a
`tacky coating of hot, melted asphalt to define a first asphalt
`coated sheet 18. In other embodiments, however, the asphalt
`coating could be sprayed on, rolled on, or applied to the sheet
`by other means. Typically, the asphalt material is highly filled
`with a ground stone filler material, amounting to at least about
`60 percent by weight of the asphalt/filler combination.
`A continuous strip of a reinforcement material or tape 19,
`as will be described in detail herein, may then be payed out
`from a roll 20. The reinforcement tape 19 adheres to the first
`asphalt coated sheet 18 to define a second asphalt coated sheet
`22. In one embodiment, the reinforcement tape 19 is attached
`to the sheet 18 by the adhesive mixture of the asphalt in the
`first asphalt coated sheet 18. The reinforcement tape 19, how-
`ever, may be attached to the sheet 18 by any suitable means,
`such as other adhesives. In one embodiment, the tape 19 is
`formed from polyester. In another embodiment, the tape 19 is
`formed from polyolefin, such as polypropylene or polyethyl-
`ene. The tape 19, however, can be formed from any material
`for reinforcing and strengthening the nail zone of a shingle,
`such as, for example, paper, film, scrim material, and woven
`or non-woven glass.
`
`20
`
`4
`The resulting second asphalt coated sheet 22 may then be
`passed beneath a series of granule dispensers 24 for the appli-
`cation of granules to the upper surface of the second asphalt
`coated sheet 22. The granule dispensers can be of any type
`suitable for depositing granules onto the asphalt coated sheet.
`A granule dispenser that can be used is a granule valve of the
`type disclosed in U.S. Pat. No. 6,610,147 to Aschenbeck. The
`initial granule blender 26 may deposit partial blend dxops of
`background granules of a first color blend on the tab portion
`10 of the second asphalt coated sheet 22 in a pattern that sets or
`establishes the trailing edge of subsequent blend drops of a
`second color blend (of an accent color) and a third color blend
`(ofa different accent color). For purposes of this patent appli-
`cation, the first color blend and the background granules are
`15 synonymous. The use of initially applied partial blend drops
`to define the trailing edge of subsequent blend drops is useful
`where accurate or sharp leading edges are possible, but accu-
`rate trailing edges at high shingle manufacturing speeds are
`difficult.
`As is well known in the art, blend drops applied to the
`asphalt coated sheet are often made up of granules of several
`different colors. For example, one particular blend drop that is
`supposed to simulate a weathered wood appearance might
`actually consist of some brown granules, some dark gray
`25 granules, and some light gray granules. When these granules
`are mixed together and applied to the sheet in a generally
`uniformly mixed manner, the overall appearance of weath-
`ered wood is achieved. For this reason, the blend drops are
`referred to as having a color blend, which gives an overall
`30 color appearance. This overall appearance may be different
`from any of the actual colors of the granules in the color
`blend. Also, blend dxops of darker and lighter shades of the
`same color, such as, for example, dark gray and light gray, are
`referred to as different color blends rather than merely differ-
`35 ent shades of one color.
`As shown in FIG. 1, the series of dispensers 24 includes
`four color blend blenders 26, 28, 30, and 32. Any desired
`number of blenders, however, can be used. The final blender
`may be the background blender 34. Each of the blenders may
`40 be supplied with granules from sources of granules, not
`shown. After the blend drops are deposited on the second
`asphalt coated sheet 22, the remaining, uncovered areas are
`still tacky with warm, uncovered asphalt, and the background
`granules from the background blender 34 will adhere to the
`45 areas that are not already covered with blend drop granules.
`After all the granules are deposited on the second asphalt
`coated sheet 22 by the series of dispensers 24, the sheet 22
`becomes a granule covered sheet 40.
`In one embodiment, the reinforcement tape 19 includes an
`50 upper surface to which granules substantially will not adhere.
`The reinforcement tape 19, however, may include an upper
`surface to which granules will adhere. For example, the appa-
`ratus 10 may include any desired means for depositing gran-
`ules onto substantially the entire second asphalt coated sheet
`55 22, except for the portion of the second asphalt coated sheet
`22 covered by the tape 19, as best shown in FIG. 2. Alter-
`nately, granules may be deposited onto substantially the
`entire second asphalt coated sheet 22, including the tape 19,
`but wherein the reinforcement tape 19 includes an upper
`60 surface to which granules substantially will not adhere.
`The granule covered sheet 40 may then be turned around a
`slate drum 44 to press the granules into the asphalt coating
`and to temporarily invert the sheet so that the excess granules
`will fall off and will be recovered and reused. Typically, the
`65 granules applied by the background blender 34 are made up
`by collecting the back[all granules falling from the slate drum
`44.
`
`FAST FELT 2015, pg. 7
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 7,836,654 B2
`
`5
`The granule covered sheet 40 may subsequently be fed
`through a rotary pattern cutter 52 which includes a bladed
`cutting cylinder 54 and a backup roll 56, as shown in FIG. 1.
`If desired, the pattern cutter 52 can cut a series of cutouts in
`the tab portion of the granule covered sheet 40, and cut a
`series of notches in the underlay portion of the granule cov-
`ered sheet 40.
`The pattern cutter 52 may also cut the granule covered
`sheet 40 into a continuous underlay sheet 66 and a continuous
`overlay sheet 68. The underlay sheet 66 may be directed to be
`aligned beneath the overlay sheet 68, and the two sheets may
`be laminated together to form a continuous laminated sheet
`70. As shown in FIG. 1, the continuous underlay sheet 66 may
`be routed on a longer path than the path of the continuous
`overlay sheet 68. Further downstream, the continuous lami-
`nated sheet 70 may be passed into contact with a rotary length
`cutter 72 that cuts the laminated sheet into individual lami-
`nated shingles 74.
`In order to facilitate synchronization of the cutting and
`laminating steps, various sensors and controls may be
`employed. For example, sensors, such as photo eyes 86 and
`88 can be used to synchronize the continuous underlay sheet
`66 with the continuous overlay sheet 68. Sensors 90 can also
`be used to synchronize the notches and cutouts of the con-
`tinuous laminated sheet with the end cutter or length cutter
`72.
`In one embodiment, the reinforcement tape may be
`attached to the shingle mat 12 prior to the application of the
`asphalt coating, as shown at 19A in FIG. 1. The tape 19A may
`be attached to the shingle mat 12 by any suitable means, such
`as hot, melted asphalt, or other adhesives.
`In another embodiment, the reinforcement tape may be
`attached to the granule covered sheet 40, as shown at 19B in
`FIG. 1. The tape 19B may be attached to the granule covered
`sheet 40 by any suitable means, such as hot, melted asphalt, or
`other adhesives.
`In another embodiment, the reinforcement tape may be
`attached to a lower surface (downwardly facing as viewed in
`FIG. 1) of the mat 12, the first asphalt coated sheet 18, the
`second asphalt coated sheet 22, or the granule covered sheet
`40, as shown at 19C and 19D in FIG. 1. The tape 19C may be
`attached to the mat 12, the first asphalt coated sheet 18, the
`second asphalt coated sheet 22, or the granule covered sheet
`40 by any suitable means, such as hot, melted asphalt, other
`ad3aesives, or suitable fasteners. In such an embodiment, the
`reinforcement tape 19C and 19D may be attached to the lower
`surface of the nail zone of either of the overlay sheet 68 or the
`underlay sheet 66, thereby reinforcing and strengthening the
`nail zone as described herein.
`It will be understood, however, that in any of the embodi-
`ments described herein, reinforcement material may be
`applied as an extruded or liquid material, such as a polymer,
`that will ad3aere to the mat 12, the first sheet 18, the second
`sheet 22, the granule covered sheet 40, orthe lower surface of
`the underlay sheet 66 or the overlay sheet 68. Additionally,
`the reinforcement material may be applied to the laminated
`roofing shingle 74, as described below.
`Referring now to FIG. 2, a laminated roofing shingle is
`shown generally at 74. In the illustrated embodiment, the
`shingle 74 includes the overlay sheet 68 attached to the under-
`lay sheet 66 and has a first end 74A and a second end 74B. The
`shingle 74 also includes a longitudinal axis A. The overlay
`sheet 68 may include a headlap portion 76 and a tab portion
`78. The headlap portion 76 may include a lower zone 76A and
`an upper zone 76B. The tab portion 78 defines a plurality of
`tabs 80 and cutouts 82 between adjacent tabs 80. In the
`illustrated embodiment, the tab portion 78 includes four tabs
`
`6
`80, although any suitable number of tabs 80 may be provided.
`The headlap portion 76 and the tabs 80 may include one or
`more granule patterns thereon. Each cutout 82 has a first
`height H1. In the illustrated embodiment, the cutouts 82 are
`5 shown as having the same height H1. It will be understood
`however, that each cutout 82 may be of different heights. A
`line B is collinear with an upper edge 82A of the cutouts 82
`and defines an upper limit of an exposed region 84 of the
`underlay sheet 66. In the illustrated embodiment, the height
`10 of the exposed region 84 is equal to the first height H1,
`although the height of the exposed region 84 may be any
`desired height, and the top of the cutouts need not be collinear
`as shown. In a shingle wherein the cutouts 82 have different
`heights, the line B may be collinear with an upper edge 82A
`15 of the cutout 82 having the largest height. In the illustrated
`embodiment, the overlay sheet 68 has a second height H2.
`The reinforcement tape 19 may be disposed longitudinally
`on the headlap portion 76. In the illustrated embodiment, the
`tape 19 extends longitudinally from the first end 74A to the
`2o second end 74B of the shingle 74 within the lower zone 76A
`of the headlap portion 76. A lower edge 19A of the tape 19
`may be spaced apart from the line B by a distance D1, and an
`upper edge 19B of the tape 19 may be spaced apart from the
`line B by a distance D2. In one embodiment, the distance D1
`25 is within the range of from about 1¼ inch to about 3¼ inch. In
`another embodiment, the distance D1 is about 1~ inch. In one
`embodiment, the distance D2 is within the range of from
`about 13¼ inches to about 21/4 inches. In another embodiment,
`the distance D2 is about 2 inches. The distances D1 and D2
`30 may, however, be of any other desired length, including zero
`for D1. For example, if desired, the tape 19 may substantially
`cover the entire headlap portion 76 of the overlay sheet 68. It
`will be further understood, however, that one or more addi-
`tional lengths of tape may be disposed longitudinally on the
`35 headlap portion 76, even outside the nail zone, such as shown
`by the phantom line 19’ in FIG. 2. It will be understood that
`the reinforcement material need not extend from the first end
`74A to the second end 74B of the shingle 74, and may be
`disposed in one or more sections or portions on the shingle 74.
`4o The tape 19 defines a nail zone 98 and may include text
`such as "nail here o", as shown in FIG. 2. It will be understood,
`however, that any other text or other indicia may be included
`on the tape 19. It will also be understood that the tape 19 can
`be provided without such text or indicia. Such indicia on the
`45 tape 19 ensure that the nail zone 98 may be easily and quickly
`identified by the shingle installer.
`In the embodiment illustrated in FIG. 2, the underlay sheet
`66 includes a leading edge 66A and a trailing edge 66B and
`has a third height H3. In the illustrated embodiment, the
`5o trailing edge 66B of the underlay sheet 66 is spaced apart
`from the line B by a distance D3. As shown, the distance D3
`is about 3/8 inch, however, the distance D3 may be any desired
`distance.
`In the illustrated embodiment, the third height H3 of the
`55 underlay sheet 66 is less than one-halfthe secondheight H2 of
`the overlay sheet 68. The overlay sheet 68 and the underlay
`sheet 66 thereby define a two-layer portion of the laminated
`shingle 74 and a single-layer portion of the laminated shingle
`74, wherein at least a portion of the tape 19 is preferably
`6o adhered to the single-layer portion of the laminated shingle
`74. Alternately, the third height H3 of the underlay sheet 66
`may be equal to one-half the second height H2 of the overlay
`sheet 68, or greater than one-half of the second height H2 of
`the overlay sheet 68. Such a relationship between the under-
`65 lay sheet 66 and the overlay sheet 68 allows the tape 19 to be
`positioned such that a reinforced nail zone is provided at a
`substantially single-layer portion of the shingle 74.
`
`FAST FELT 2015, pg. 8
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`US 7,836,654 B2
`
`7
`In another embodiment of the invention, a layer of mate-
`rial, such as talc or sand, may be applied to the first asphalt
`coated sheet 18 shown in FIG. 1. The material may be applied
`by any desired means to an upper surface of the first asphalt
`coated sheet 18. In one embodiment, the material may be
`applied to the portion of the first asphalt coated sheet 18 that
`will become the portion of the overlay sheet 66 shown cov-
`ered by the tape 19 in FIG. 2. Such a material may reduce
`tackiness of the portions of the second asphalt coated sheet 22
`to which the material has been applied, and thereby provide a
`surface to which granules substantially will not adhere and/or
`which creates a visible line in the overlay illustrated by the
`nail zone 98.
`In the exemplary shingle 74 illustrated in FIG. 2, the
`shingle 74 may have a nail pull-through value, measured in
`accordance with a desired standard, such as prescribed by
`ASTM test standard D3462. For example, the shingle 74 may
`have a nail pull-through value that is greater than in an oth-
`erwise identical shingle having no such tape 19. In one
`embodiment, the shingle 74 may have a nail pull-through
`value within the range of from about ten percent to about 100
`percent greater than in an otherwise identical shingle having
`no such tape 19. In another embodiment, the shingle 74 may
`have a nail pull-through value about 50 percent greater than in
`an otherwise identical shingle having no such tape 19.
`In another embodiment, a shingle having a reinforcement
`tape 19 formed from polyester film having a thickness of
`about 0.5 mils, may have a nail pull-through value about 13.3
`percent greater than in an otherwise identical shingle having
`no such tape 19.
`In another embodiment, a shingle having a reinforcement
`tape 19 formed from polyester film having a thickness of
`about 3.0 mils, may have a nail pull-through value about 62.3
`percent greater than in an otherwise identical shingle having
`no such tape 19.
`In another embodiment, a shingle having a reinforcement
`tape 19 formed from polyester film having a thickness of
`about 4.0 mils, may have a nail pull-through value about 86.0
`percent greater than in an otherwise identical shingle having
`no such tape 19.
`In another embodiment, a shingle having a reinforcement
`tape 19 formed from polyester film having a thickness of
`about 5.0 mils, may have a nail pull-through value about
`112.7 percent greater than in an otherwise identical shingle
`having no such tape 19.
`Because there may be substantially no granules in the
`portion of the overlay sheet 68 covered by the tape 19, the
`weight of the shingle 74 may be reduced relative to an other-
`wise identical shingle having no such tape 19. For example,
`the weight of the exemplary shingle 74 illustrated in FIG. 2,
`may be reduced within the range of from about four percent to
`about six percent relative to the weight of an otherwise iden-
`tical shingle having no such tape 19. The material and trans-
`portation cost may also be reduced. In the embodiment where
`the tape 19 is applied to the entire headlap portion 76, the
`weight savings may approach 15 percent, 20 percent or more
`(in either single layer or laminated shingles).
`Although the invention has been disclosed in the context of
`a laminated shingle 74, it will be understood that the rein-
`forcement tape 19 may be attached to any other type of
`shingle, such as a single layer shingle. In such a single layer
`shingle, the reinforcement tape may require UV resistance
`and/or appropriate coloration if the shingle has tab cutouts
`and if the tape is visible through the cutouts, and may require
`electrostatic frosting or other non-glare treatment. In a typical
`single layer shingle with cutouts, typically a band is provided
`at the top of the shingle w