Shingle layer or shingle having thick appearance

Abstract

A shingle layer of shingle is provided having an increased thickness adhesive coating on at least a portion of its rear surface, with granules embedded therein, with the granules being of a size range that is larger than the fine particles normally applied to the rear surface of a shingle layer.

1 . A shingle layer having a front surface and a rear surface and comprising a bitumen-coated web; 
 (a) with the front surface having a tab portion normally exposed when in use on a roof;    (b) with the front surface having a butt portion normally unexposed when in use on a roof;    (c) with the rear surface having a first zone behind said tab portion and a second zone behind said butt portion;    (d) a front layer of granules of a size range from about 0.3 to about 3 mm on at least the tab portion of the front surface;    (e) an adhesive coating of a thickness within the range of about 0.1 to about 2 mm on at least a portion of the first zone of the rear surface;    (f) a rear layer of granules of a size range from about 0.3 to about 3 mm embedded in said adhesive coating;    (g) the thickness of the shingle layer between the tab portion of the front surface and the first zone of the rear surface being substantially uniform;    (h) whereby the rear layer of granules provides an appearance of thickness to the shingle layer.    
   
   
       2 . The shingle of  claim 1 , wherein said adhesive coating comprises bitumen from the bitumen-coated web and wherein the rear layer of granules is adhered directly to the bitumen-coated web.  
   
   
       3 . The shingle layer of  claim 1 , wherein the rear layer of granules comprises an overlay that is adhered to the adhesive coating, that, in turn, is disposed against a layer of fine particles of a size range from about 0.05 to about 0.6 mm, with the layer of fine particles being adhered to the bitumen-coated web.  
   
   
       4 . The shingle layer of  claim 1 , wherein the rear layer of granules comprises an overlay that is adhered to the adhesive coating, that, in turn, is disposed against a layer of particles of a size range from about 0.3 to about 3 mm, with the layer of particles being adhered to the bitumen-coated web.  
   
   
       5 . The shingle layer of  claim 1 , wherein the adhesive coating and the rear layer of granules comprise a first overlay on the rear surface, and the shingle layer further comprises a second overlay adhered to at least a portion of said first overlay, said second overlay comprising a second rear layer of granules and a second adhesive coating.  
   
   
       6 . The shingle layer of  claim 1 , wherein the front layer of granules covers substantially the entire front surface of the shingle layer.  
   
   
       7 . The shingle layer of  claim 1 , wherein the rear layer of granules covers substantially the entire rear surface of the shingle layer.  
   
   
       8 . The shingle layer of  claim 1 , wherein the rear layer of granules is in a predetermined pattern on the rear surface.  
   
   
       9 . The shingle layer of  claim 1 , wherein the shingle layer comprises a shingle.  
   
   
       10 . The shingle layer of  claim 1 , wherein the shingle layer comprises the top shingle layer of a laminated multiple-layer shingle.  
   
   
       11 . The shingle layer of  claim 1 , wherein the butt portion of the shingle layer has a top edge and the tab portion of the shingle layer has a bottom edge; with the shingle layer having end edges at opposite ends, connecting said top and bottom edges; with the rear layer of granules being adhered to the adhesive coating, at least along said bottom edge.  
   
   
       12 . The shingle layer of  claim 1 , wherein said adhesive coating comprises bitumen from the bitumen-coated web and wherein the rear layer of granules is adhered directly to the bitumen-coated web, wherein the shingle layer comprises a shingle.  
   
   
       13 . The shingle layer of  claim 1 , wherein the rear layer of granules comprises an overlay that is adhered to the adhesive coating disposed against a layer of fine particles of a size range from about 0.05 to about 0.6 mm, with the layer of fine particles being adhered to the bitumen-coated web and wherein the shingle layer comprises a shingle.  
   
   
       14 . The shingle layer of  claim 1  wherein the rear layer of granules comprises an overlay that is adhered to the adhesive coating disposed against a layer of particles of a size range from about 0.3 to about 3 mm, with the layer of particles being adhered to the bitumen-coated web and wherein the shingle layer comprises a shingle.  
   
   
       15 . A method of making a shingle layer, the method comprising the steps of; 
 (a) providing a web;    (b) coating the web with bitumen to yield a bitumen coated web having a front surface and a rear surface;    (c) denoting a tab portion and a butt portion of the web;    (d) adhering a front layer of granules to the front surface of the web to yield a granule coated front surface;    (e) adhering an adhesive coating to at least a first zone of the rear surface of the tab portion; and,    (f) adhering a rear layer of granules to the first zone of the rear surface of the tab portion such that the thickness of the shingle layer between the granule coated front surface and the granule coated rear surface of the tab portion is substantially uniform.    
   
   
       16 . A method of enhancing the apparent thickness of a shingle layer, the method comprising the steps of; 
 (a) providing a shingle layer having a front surface and a rear surface, the shingle layer having an upper edge, a lower edge, a tab portion and a butt portion and a first zone of the rear surface of the tab portion; and,    (b) adhering a rear layer of granules to the first zone of the rear surface of the tab portion by means of an adhesive coating such that the thickness of the shingle layer between the granule coated front surface and the granule coated rear surface of the tab portion is substantially uniform.