# US 11,077,653 B2 · Asphalt shingle, roof covering therewith and method of making the same with synchronized adhesive positioning thereon > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,077,653 B2 - Document ID: US11077653B2 - Status: Granted - Kind: B2 - Application number: 16/821,554 - Filed: 2020-03-17 - Published: 2020-12-10 - Granted: 2021-08-03 - Earliest claimed: 2009-09-16 - Assignees: CertainTeed Corporation - Applicants: CertainTeed LLC - Inventors: Robert L. Jenkins - Web page: https://patentgrep.com/patent/US11077653B2 ## CPC - B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) - B32B 37/1292: {selectively, e.g. in stripes, in patterns (B32B37/0076 takes precedence)} - B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)} - B32B 41/00: Arrangements for controlling or monitoring lamination processes; Safety arrangements - E04D 1/26: Strip-shaped roofing elements {simulating a repetitive pattern, e.g.} appearing as a row of shingles - B32B 2305/076: Prepregs - B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips - B32B 2419/06: Roofs, roof membranes - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00) ## Abstract A method of making the asphalt shingles includes applying a substrate to a layer of shingle-forming material, the substrate having indicators at predetermined spaced-apart distances, with the indicators being sensed as the shingle-forming layer is moved along a predetermined path, with adhesive zones being applied to the shingle such that the application of the adhesive zones is synchronized in response to sensing the locations of the indicators, and with the shingle-forming layer then being cut into individual shingles. ## Claims ### Claim 1 A method of making an asphalt shingle in a manufacturing environment, in which the shingle has a headlap region and a tab region, with granules applied to an upper surface of the shingle that is to be weather-exposed in the installed condition on a roof, the method comprising: providing a shingle-forming layer comprising a shingle reinforcement material impregnated with a bitumen material, and a layer of granules disposed on an upper surface of the bitumen material of the shingle-forming layer, the shingle-forming layer having a plurality of indicators disposed thereon delivering the layer along a predetermined path; sensing the locations of the indicators; then actuating the placement of adhesive zones onto the upper surface of headlap portions of the shingle-forming layer and synchronizing the placement of the adhesive zones on the upper surface of the shingle-forming layer in response to the sensing step; and cutting the shingle-forming layer into individual shingles, each having a headlap region and a tab region, wherein the tab region of each individual shingle comprises a plurality of tabs defined by slots formed through the entire thickness of the shingle and extending from a lower edge of the tab region to the butt region, each tab having a centerline, each slot having a length L and a width W, and wherein the adhesive zones are placed leaving adhesive-free zones on the upper surface of the headlap region registered with the centerlines of the tabs, such that no adhesive is disposed in registration with the centerlines, each adhesive-free zone having a length of at least L and a width of at least W. ### Claim 2 (depends on 1) The method of claim 1, including the step of cutting slots in the tab region of the shingle-forming layer to separate the tab region into a plurality of spaced-apart tabs. ### Claim 3 (depends on 2) The method of claim 2, wherein the slot cutting step includes synchronizing the placement of the slots in the shingle-forming layer in response to the sensing step. ### Claim 4 (depends on 1) The method of claim 1, wherein the synchronizing step includes changing the relative placement of any of: (a) the adhesive zones; and (b) the slots in response to the sensing step. ### Claim 5 (depends on 4) The method of claim 4, wherein the placement of adhesive zones is done with an adhesive applicator and wherein the placement of slots is done with a slot cutter, and wherein the step of changing the relative placement includes effecting a change in the delivering of the shingle-forming layer to any of: (a) the adhesive applicator; and (b) the slot cutter. ### Claim 6 (depends on 4) The method of claim 4, wherein the step of changing the relative placement includes effecting a change in position of any of: (a) the adhesive applicator; and (b) the slot cutter relative to the delivering of the shingle-forming layer. ### Claim 7 (depends on 2) The method of claim 2, wherein the synchronizing step includes changing the relative placement of any of: (a) the adhesive zones; and (b) the slots in response to the sensing step. ### Claim 8 (depends on 7) The method of claim 7, wherein the placement of adhesive zones is done with an adhesive applicator and wherein the placement of slots is done with a slot cutter, and wherein the step of changing the relative placement includes effecting a change in the delivering of the shingle-forming layer to any of: (a) the adhesive applicator; and (b) the slot cutter. ### Claim 9 (depends on 7) The method of claim 7, wherein the step of changing the relative placement includes effecting a change in position of any of: (a) the adhesive applicator; and (b) the slot cutter relative to the delivering of the shingle-forming layer. ### Claim 10 (depends on 3) The method of claim 3, wherein the synchronizing step includes changing the relative placement of any of: (a) the adhesive zones; and (b) the slots in response to the sensing step. ### Claim 11 (depends on 10) The method of claim 10, wherein the placement of adhesive zones is done with an adhesive applicator and wherein the placement of slots is done with a slot cutter, and wherein the step of changing the relative placement includes effecting a change in the delivering of the shingle-forming layer to any of: (a) the adhesive applicator; and (b) the slot cutter. ### Claim 12 (depends on 10) The method of claim 10, wherein the step of changing the relative placement includes effecting a change in position of any of: (a) the adhesive applicator; and (b) the slot cutter relative to the delivering of the shingle-forming layer. ### Claim 13 (depends on 1) The method of claim 1, wherein the indicators comprise physical marks disposed at a surface of the of the shingle-forming layer. ### Claim 14 (depends on 13) The method of claim 13, wherein the physical marks comprise holes. ### Claim 15 (depends on 1) The method of claim 1, wherein the indicators are sensed by a magnetic detection device, an infrared device, a barcode reader, a metal detection device, a hole detection device, a CCD image reader, or a photocell. ### Claim 16 (depends on 1) The method of claim 1, wherein the indicators are provided by a tape bearing indicators disposed on a surface of the shingle-forming layer. ### Claim 17 A method of making an asphalt shingle in a manufacturing environment, in which the shingle has a headlap region and a tab region, with granules applied to an upper surface of the shingle that is to be weather-exposed in the installed condition on a roof, the method comprising: providing a shingle-forming layer comprising a shingle reinforcement material impregnated with a bitumen material, and a layer of granules disposed on an upper surface of the bitumen material of the shingle-forming layer, the shingle-forming layer having a plurality of indicators disposed thereon; delivering the layer along a predetermined path; sensing the locations of the indicators; then actuating the placement of adhesive zones onto the upper surface of headlap portions of the shingle-forming layer and synchronizing the placement of the adhesive zones on the upper surface of the shingle-forming layer in response to the sensing step; and cutting the shingle-forming layer into individual shingles, each having a headlap region and a tab region, wherein the tab region of each individual shingle comprises a plurality of tabs defined by slots formed through the entire thickness of the shingle and extending from a lower edge of the tab region to the butt region, each slot having a length L and a width W, and wherein the adhesive zones are placed leaving adhesive-free zones on the upper surface of the headlap region registered with a first lateral position in a central portion of each tab, such that no adhesive is disposed in registration with each such first lateral position, each such first lateral position being disposed laterally within each tab at an identical lateral location, each adhesive-free zone having a length of at least L and a width of at least W. ### Claim 18 A method of making an asphalt shingle in a manufacturing environment, in which the shingle has a headlap region and a tab region, with granules applied to an upper surface of the shingle that is to be weather-exposed in the installed condition on a roof, the method comprising: providing a shingle-forming layer comprising a shingle reinforcement material impregnated with a bitumen material, and a layer of granules disposed on an upper surface of the bitumen material of the shingle-forming layer, the shingle-forming layer having a plurality of indicators disposed thereon; delivering the layer along a predetermined path; sensing the locations of the indicators; then actuating the placement of adhesive zones onto the upper surface of headlap portions of the shingle-forming layer and synchronizing the placement of the adhesive zones on the upper surface of the shingle-forming layer in response to the sensing step of clause (d); and cutting the shingle-forming layer into individual shingles, each having a headlap region and a tab region, wherein the tab region of each individual shingle comprises a plurality of tabs defined by slots formed through the entire thickness of the shingle and extending from a lower edge of the tab region to the butt region, each slot having a length L and a width W, and wherein the adhesive zones are placed leaving adhesive-free zones on the upper surface of the headlap region registered with a lateral position in a central portion of each tab, each adhesive-free zone having a length of at least L and a width of at least W, such that no adhesive is disposed in registration with each such lateral position, and such when a plurality of such shingles are laid up in courses on a roof, with shingles in the same course being laid with their right and left edges adjacent to right and left edges of other of said shingles and wherein shingles in overlying courses are offset longitudinally relative to shingles in next-underlying courses, with tabs of shingles in overlying courses covering adhesive stripes in headlap portions of shingles in next-underlying courses, the adhesive-free zones in headlap portions of shingles in next-underlying courses are in registration with slots of shingles in overlying courses, such that no adhesive of a shingle of an underlying course is visible through slots of shingles in a next-overlying course.