Stock material or miscellaneous articles – Structurally defined web or sheet – Continuous and nonuniform or irregular surface on layer or...
Reexamination Certificate
1997-12-24
2001-02-20
Watkins, III, William P. (Department: 1772)
Stock material or miscellaneous articles
Structurally defined web or sheet
Continuous and nonuniform or irregular surface on layer or...
C428S144000, C428S145000, C428S149000, C428S150000, C428S195100, C428S207000, C052S555000, C052S554000, C052S518000, C052S540000, C052S557000, C156S260000, C156S264000, C427S186000, C427S187000, C427S188000, CD25S139000, CD25S149000
Reexamination Certificate
active
06190754
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to shingle products, such as shingles used in the roofing industry. More particularly, the present invention pertains to a shingle and method of manufacturing the shingle in which coloration along the shingle is variegated.
2. Description of Related Art
Roofing products having an outer layer of mineral or synthetic granules, such as asphalt shingles, are well known for use on roofs. Such shingles provide a relatively inexpensive alternative to wood shingles, among others. In addition, asphalt shingles are advantageous from the standpoint of fire resistance and durability. Manufacturers of asphalt shingles, however, continue to seek to replicate the thickness and shading afforded by wood shingles.
Prior attempts to enhance the appearance of thickness and corresponding depth in asphalt shingles are reflected in U.S. Pat. Nos. 5,369,929 and 5,611,186, for example. These patents disclose composite shingle products having a plurality of horizontal striations or bands. The shading, i.e. color value, of the striations differs from one striation to the next; however, the shading within each striation is substantially uniform. Consequently, the conventional striated shingle produces substantially uniform patterns of horizontal bands. The banding or checkerboard effect is exacerbated when like shingles are assembled to form a roof covering.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to an improved shingle and method of manufacturing shingles and shingle components that substantially obviates one or more of the limitations of the related art.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described in this application, the shingle comprises a shingle layer having front and rear surfaces, the front surface including a butt portion and a headlap portion. The shingle layer contains granules on the front surface forming a plurality of horizontal striations providing gradations having color values ranging from light to dark extending between a leading edge of the butt portion and an upper portion thereof. The striations include an upper striation along the upper portion, a lower striation closer to the leading edge, and an intermediate striation between the upper and lower striations. The upper striation is darker in color value than the lower striation, whereas the intermediate striation is no darker in color value than the upper striation and no lighter in color value than the lower striation. Significantly, the color values of at least one of the upper, lower, and intermediate striations vary across the granule layer.
In a preferred embodiment, the intermediate striation varies in color value at least once between one side of the granule layer and an opposite side.
Preferably, the shingle of the present invention is a multi-layer laminated shingle also known as a composite shingle. The roof shingle of the present invention also may be formed from a single strip single, such as a three-tabbed shingle.
In addition, the present invention comprises a method of fabricating roof shingle components from an asphalt-coated sheet comprising the steps of depositing colored granules on the asphalt-coated sheet to form continuous parallel bands shaded to provide a color gradation from light to dark on a striated portion of the sheet; and continuously varying the shading of at least one of the bands applied to the sheet.
The method of the present invention also may include the step of cutting the sheet to form a single layer strip shingle. Alternatively, the present invention contemplates cutting the sheet to form a first shingle layer having a row of tabs and openings individually interposed between consecutive ones of the tabs; cutting the striated portion of the sheet to form a second shingle layer; and securing the first shingle layer to the second shingle layer so that the striated portion of the sheet is visible through the openings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
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Bondoc Alfredo A.
Carroll William R.
Sieling Frederick W.
Building Materials Corporation of America
Davis William J.
Foley Christopher P.
Watkins III William P.
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