Shingles and methods of producing shingles

Abstract

The present specification describes shingles having first and second discrete portions. A fastening member, such as a rivet, secures the first and second portions to one another. The rivet resists separation of the portions over time after the shingles have been installed on a rooftop. The present specification also describes methods of producing shingles having at least one fastening member to secure first and second shingle portions to one another. In one method, apparatus is provided to puncture a continuous strip of shingles at regular intervals, and then insert a fastening member into the apertures created during the puncturing step. The puncturing and injecting apparatus described includes drums, which the shingle strip may pass over or under.

1 . A shingle adapted to be secured to a rooftop to prevent moisture from penetrating the rooftop, comprising: 
 a first portion;    a second portion partially overlapping the first portion, thereby defining an overlapping region;    at least one aperture extending through both portions in the overlapping region; and    a fastening member extending through the at least one aperture.    
     
     
         2 . The shingle of  claim 1 , wherein the at least one fastening member comprises spaced end portions that abut an upper surface and a lower surface, respectively, of the shingle.  
     
     
         3 . The shingle of  claim 2 , wherein the at least one fastening member comprises a shaft portion that connects the spaced end portions.  
     
     
         4 . The shingle of  claim 1 , wherein the at least one fastening member comprises a plastic, a nylon, a polyester, a polymer material, a polypropylene, a metal, a metal alloy, a non-metal alloy, a fiberglass or an injectable adhesive.  
     
     
         5 . The shingle of  claim 1 , wherein the first and second portions each comprise a membrane with a sticky substance covering at least a significant portion of an upper surface thereof, and a particulate substance covering at least a significant portion of the sticky substance.  
     
     
         6 . The shingle of  claim 5 , wherein the membrane comprises fiberglass.  
     
     
         7 . The shingle of  claim 5 , wherein the sticky substance comprises asphalt tar.  
     
     
         8 . The shingle of  claim 5 , wherein the particulate substance comprises sand.  
     
     
         9 . Apparatus for producing shingles, comprising: 
 a strip of shingles;    a first drum including puncturing apparatus; and    a second drum including injecting apparatus, the second drum being spaced from the first drum and positioned such that longitudinal axes of the drums are substantially parallel;    wherein the drums are adapted to contact the strip along an outer surface or outer surfaces thereof.    
     
     
         10 . The apparatus of  claim 9 , wherein the puncturing apparatus comprises at least one spike, or at least one water jet, or at least one air jet or at least one laser cutter.  
     
     
         11 . The apparatus of  claim 9 , wherein the injecting apparatus comprises at least one nozzle adapted to dispense a liquefied material.  
     
     
         12 . The apparatus of  claim 9 , further comprising a pair of pinch rollers adapted to receive the strip therebetween.  
     
     
         13 . A method of producing shingles, the method comprising the steps of: 
 providing at least one shingle having a tab portion, a tooth portion and an overlapping region in which the tab portion and tooth portion overlap;    puncturing the at least one shingle in the overlapping region to produce an aperture; and    inserting a fastening member into the aperture to secure the tab portion to the tooth portion.    
     
     
         14 . The method of  claim 13 , wherein during the puncturing step the at least one shingle passes over a substantially cylindrical drum.  
     
     
         15 . The method of  claim 14 , wherein the drum includes puncturing apparatus.  
     
     
         16 . The method of  claim 15 , wherein the puncturing apparatus comprises at least one spike, or at least one water jet, or at least one air jet or at least one laser cutter.  
     
     
         17 . The method of  claim 13 , wherein during the inserting step the at least one shingle passes over a substantially cylindrical drum.  
     
     
         18 . The method of  claim 17 , wherein the drum includes injecting apparatus.  
     
     
         19 . The method of  claim 18 , wherein the injecting apparatus comprises at least one nozzle adapted to dispense a liquefied material.  
     
     
         20 . The method of  claim 18 , wherein the injecting apparatus injects a liquefied material into the aperture, and the liquefied material hardens to form a fastening member.  
     
     
         21 . The method of  claim 20 , wherein the liquefied material comprises a plastic, a nylon, a polyester, a polymer material, a polypropylene, a metal, a metal alloy, a non-metal alloy, a fiberglass or an injectable adhesive.  
     
     
         22 . The method of  claim 13 , further comprising the step of flattening end portions of the fastening member.  
     
     
         23 . Apparatus for producing shingles, comprising: 
 a strip of shingles;    an outer drum;    a first drum including puncturing apparatus; and    a second drum including injecting apparatus, the second drum being spaced from the first drum and positioned such that longitudinal axes of the drums are substantially parallel;    wherein the outer drum is adapted to contact the strip along an outer surface thereof, the first drum is adapted to puncture the strip as it passes by the outer drum, and the second drum is adapted to inject a fastening member into the strip as it passes by the outer drum.