Method of manufacturing a shingle

Abstract

A roofing shingle includes a headlap portion and a tab portion. A layer of a first granular material is adhered to a back side of the headlap portion and defines a first surface. A bead of tab sealant extends longitudinally on a back side of the tab portion. A longitudinally extending groove is formed in the first surface of the back side of the headlap portion.

1 . A roofing shingle comprising:
 a headlap portion and a tab portion, a layer of a first granular material adhered to a back side of the headlap portion and defining a first surface;   a bead of tab sealant extending longitudinally on a back side of the tab portion; and   a longitudinally extending groove formed in the first surface of the back side of the headlap portion.   
     
     
         2 . The roofing shingle according to  claim 1 , wherein the longitudinally extending groove is defined by a second granular material having a granule size relatively smaller than the first granular material. 
     
     
         3 . The roofing shingle according to  claim 2 , wherein the second granular material is formed from sand. 
     
     
         4 . The roofing shingle according to  claim 2 , wherein the second granular material is formed from materials having a finer grade than the first granular material. 
     
     
         5 . The roofing shingle according to  claim 1 , wherein the longitudinally extending bead of tab sealant and the longitudinally extending groove are configured such that when a plurality of the roofing shingles are stacked in a bundle such that every other of the roofing shingles is inverted and turned 180 degrees relative to an adjacent one of the roofing shingles, the bead of tab sealant aligns with and nests within the longitudinally extending groove of an adjacent one of the roofing shingles. 
     
     
         6 . The roofing shingle according to  claim 5 , wherein leading and trailing edges of the roofing shingles define edge zones of the bundle, wherein the nesting of the bead of tab sealant within the longitudinally extending groove of the stacked shingles results in the edge zones of the bundle having a height substantially identical to a height of a remainder of the bundle outside of edge zones. 
     
     
         7 . The roofing shingle according to  claim 1 , further including a strip of material disposed within the longitudinally extending groove. 
     
     
         8 . The roofing shingle according to  claim 7 , wherein the strip of material is formed from compressible material. 
     
     
         9 . The roofing shingle according to  claim 8 , wherein the longitudinally extending bead of tab sealant and the strip of material are configured such that when a plurality of the roofing shingles are stacked in a bundle such that every other of the roofing shingles is inverted and turned 180 degrees relative to an adjacent one of the roofing shingles, the bead of tab sealant aligns with and engages the strip of material of an adjacent one of the roofing shingles. 
     
     
         10 . The roofing shingle according to  claim 9 , wherein when the plurality of the roofing shingles are stacked in the bundle, an outwardly facing surface of the strip of material is compressed by the bead of tab sealant of an adjacent one of the roofing shingles and defines a groove within the strip of material, and wherein the bead of tab sealant nests within the groove formed within the strip of material of an adjacent one of the roofing shingles. 
     
     
         11 . The roofing shingle according to  claim 10 , wherein leading and trailing edges of the roofing shingles define edge zones of the bundle, and wherein the nesting of the bead of tab sealant within the groove formed within the strip of material of an adjacent one of the roofing shingles results in the edge zones of the bundle having a height substantially identical to a height of a remainder of the bundle outside of edge zones. 
     
     
         12 . The roofing shingle according to  claim 1 , wherein the groove has a width within the range of from about 0.0625 inches to about 0.25 inches larger than a width of the bead of tab sealant. 
     
     
         13 . A roofing shingle comprising:
 a headlap portion and a tab portion, a layer of a first granular material adhered to a back side of the headlap portion and defining a first surface;   a bead of tab sealant extending longitudinally on a back side of the tab portion; and   a longitudinally extending groove formed in the first surface of the back side of the headlap portion, wherein the longitudinally extending groove is defined by a second granular material having a granule size relatively smaller than the first granular material, wherein the longitudinally extending bead of tab sealant and the longitudinally extending groove are configured such that when a plurality of the roofing shingles are stacked in a bundle such that every other of the roofing shingles is inverted and turned  180  degrees relative to an adjacent one of the roofing shingles, the bead of tab sealant aligns with and nests within the longitudinally extending groove of an adjacent one of the roofing shingles, wherein leading and trailing edges of the roofing shingles define edge zones of the bundle, and wherein the nesting of the bead of tab sealant within the longitudinally extending groove of the stacked shingles results in the edge zones of the bundle having a height substantially identical to a height of a remainder of the bundle outside of edge zones.   
     
     
         14 . A roofing shingle comprising:
 an overlay sheet including a headlap portion and a tab portion, a layer of a first granular material adhered to a back side of the headlap portion and defining a first surface;   an underlay sheet secured to the overlay sheet such that a region of the underlay sheet overlaps a region of the headlap portion of the overlay sheet, thereby defining a two-layer portion and a single-layer portion of the roofing shingle;   a bead of tab sealant extending longitudinally on a back side of the underlay sheet; and   a longitudinally extending groove formed in the first surface of the back side of the headlap portion.   
     
     
         15 . The roofing shingle according to  claim 14 , wherein the longitudinally extending groove is defined by a second granular material having a granule size relatively smaller than the first granular material. 
     
     
         16 . The roofing shingle according to  claim 15 , wherein the second granular material is formed from sand. 
     
     
         17 . The roofing shingle according to  claim 15 , wherein the second granular material is formed from materials having a finer grade than the first granular material. 
     
     
         18 . The roofing shingle according to  claim 14 , wherein the longitudinally extending bead of tab sealant and the longitudinally extending groove are configured such that when a plurality of the roofing shingles are stacked in a bundle such that every other of the roofing shingles is inverted and turned 180 degrees relative to an adjacent one of the roofing shingles, the bead of tab sealant aligns with and nests within the longitudinally extending groove of an adjacent one of the roofing shingles. 
     
     
         19 . The roofing shingle according to  claim 18 , wherein leading and trailing edges of the roofing shingles define edge zones of the bundle, wherein the nesting of the bead of tab sealant within the longitudinally extending groove of the stacked shingles results in the edge zones of the bundle having a height substantially identical to a height of a remainder of the bundle outside of edge zones. 
     
     
         20 . The roofing shingle according to  claim 14 , further including a strip of material disposed within the longitudinally extending groove. 
     
     
         21 . The roofing shingle according to  claim 20 , wherein the strip of material is formed from compressible material. 
     
     
         22 . The roofing shingle according to  claim 21 , wherein the longitudinally extending bead of tab sealant and the strip of material are configured such that when a plurality of the roofing shingles are stacked in a bundle such that every other of the roofing shingles is inverted and turned 180 degrees relative to an adjacent one of the roofing shingles, the bead of tab sealant aligns with and engages the strip of material of an adjacent one of the roofing shingles. 
     
     
         23 . The roofing shingle according to  claim 22 , wherein when the plurality of the roofing shingles are stacked in the bundle, an outwardly facing surface of the strip of material is compressed by the bead of tab sealant of an adjacent one of the roofing shingles and defines a groove within the strip of material, and wherein the bead of tab sealant nests within the groove formed within the strip of material of an adjacent one of the roofing shingles. 
     
     
         24 . The roofing shingle according to  claim 23 , wherein leading and trailing edges of the roofing shingles define edge zones of the bundle, and wherein the nesting of the bead of tab sealant within the groove formed within the strip of material of an adjacent one of the roofing shingles results in the edge zones of the bundle having a height substantially identical to a height of a remainder of the bundle outside of edge zones. 
     
     
         25 . The roofing shingle according to  claim 14 , wherein the groove has a width within the range of from about 0.0625 inches to about 0.25 inches larger than a width of the bead of tab sealant.