Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: A roofing material, such as laminated shingles, comprising fines deposited on an upper surface of the roofing material, particularly on one or more non-weathering regions, such as on the headlap region, and/or shim layer. The fines may be deposited, for example, as a strip from about 0.5 inches to about 2.5 inches in width and extend the length of the roofing material at a fixed position from one edge of the roofing material to the opposite edge of the roofing material. The fines may comprise mica flakes, copper slag, coal slag, sand, talc, expanded clay, slate flour, powdered limestone or silica dust.

Abstract: This invention relates to an improved fastening technique for single ply roofing membranes comprised of thermoplastic polymer material. In one embodiment, a method of installing a roof on a structure may comprise providing a single-ply roofing membrane comprising thermoplastic polymer material, and periodically securing rigid strips over a roofing deck. In such embodiment, the rigid strips have thermoplastic polymer material on corresponding exterior surfaces thereof. The method may further include laying the roofing membrane over the roofing deck, where the rigid strips are located between the roofing deck and the roofing membrane. Then the method may include heating the roofing membrane and the rigid strips simultaneously, perhaps using a heat induction technique, such that thermoplastic polymer material on the exterior surfaces of the rigid strips fuses directly with the thermoplastic polymer material of the roofing membrane.

Abstract: Disclosed herein are photovoltaic building materials and related methods of manufacturing and installing such materials. In one embodiment, a modular roofing structure comprises a photovoltaic shingle panel having a planar lower surface and an upper surface, and a rigid back member having a length the same as or greater than the length of the shingle panel and attached to the planar lower surface of the shingle panel. The roofing structure also includes at least one electrical contact pad on a lower surface of the back member, and at least one electrical conductor electrically coupled to the shingle panel via the lower surface and passing through the back member and out the lower surface. In such embodiments, the electrical conductor is electrically coupled to the at least one contact pad and extends past a front end of the back member sufficient to electrically contact a contact pad on another back member of a separate modular roofing structure couplable to the first.

Abstract: The present invention relates to roofing materials for roofs, sidewalls and other exterior surfaces exposed to the weather such as, but not limited to, asphaltic and non-asphaltic roofing materials, wherein metal flakes cover up to 100% of the weathering surface of the roofing materials. The metal flakes may be applied to the surface in striations or bands separated by conventional roofing granules or may be blended with conventional roofing granules. The metal flakes may have antimicrobial potential and may provide resistance to microbial growth to roofing materials when dispersed in or applied thereto. The present invention also relates to methods of making the roofing materials.

Abstract: Disclosed herein are photovoltaic building materials and related methods of manufacturing and installing such materials. In one embodiment, a modular roofing structure comprises a photovoltaic shingle panel having a planar lower surface and an upper surface, and a rigid back member having a length the same as or greater than the length of the shingle panel and attached to the planar lower surface of the shingle panel. The roofing structure also includes at least one electrical contact pad on a lower surface of the back member, and at least one electrical conductor electrically coupled to the shingle panel via the lower surface and passing through the back member and out the lower surface. In such embodiments, the electrical conductor is electrically coupled to the at least one contact pad and extends past a front end of the back member sufficient to electrically contact a contact pad on another back member of a separate modular roofing structure couplable to the first.

Abstract: A composite material comprising a first layer which comprises a surfactant component, surfactant-generated microcells, a gel catalyst component and a binder component, and a second layer which comprises a metallic component is provided. The first layer may further comprise a filler component. In addition, the composite material may further comprise a substrate to which the first layer is adhered. The composite materials have heat insulating and fire resistant characteristics and are particularly suited for use in building materials and mattresses.

Abstract: The present invention relates to roofing materials for roofs, sidewalls and other exterior surfaces exposed to the weather such as, but not limited to, asphaltic and non-asphaltic roofing materials, wherein color coated metal flakes cover up to 100% of the weathering surface of the roofing materials. The metal flakes are coated with a colored coating material by fluidizing the flakes in an air stream, spraying pressurized air and colored coating material, and curing the coated metal flakes. The present invention also relates to methods of making roofing materials.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Roofing material consists essentially of a substrate, a hot melt material applied to one side of the substrate, an asphalt material coating the other side of the substrate and roofing granules disposed on said asphalt material coated on the substrate. The hot melt material may be polyethylene, polyethylene-vinyl acetate, polypropylene, polyvinylidene chloride, polyester, nylon and mixtures thereof. The asphalt material may include non-asphaltic filler.

Abstract: A single layer roofing material having a headlap portion and a tab portion wherein the headlap portion has a color-value gradient or gradation and the tab portion has tabs and openings. The tabs may have a relatively uniform color. Openings between tabs expose the color gradient of the headlap portion when a first sheet of the roofing material is installed over a second sheet on a structure. A plurality of horizontal striations may be used to establish the desired color-value gradient. An illusion of depth or thickness is created when the roofing material is applied to a structure, such as a roof deck. The amount of tone and contrast may be selected to create the desired illusion of depth or thickness. The amount of contrast may be varied depending upon the color selected for each roofing material. The number of horizontal striations and their width may also be varied to provide the desired color-value gradient. Tab color, shape and size may also be varied to enhance the illusion of depth.

Abstract: A roofing system having a multiplicity of courses of roofing shingles and interply material having at least one course of interply material overlapping at least about ten percent of a first course of shingles and a second course of shingles overlapping at least a portion of the interply material and the first course of shingles. More than about 40% of the first course of shingles is exposed after installation. The roofing system has a class A fire resistant rating. Roofing shingles having particular utility in the roofing system of the present invention are also disclosed. In preferred embodiments the shingles have an exposure width of at least about 60% of the shingle, more preferably at least about 64% of the width of the shingle.

Abstract: A fastener-free composite roofing product comprising a roofing material and an interply material attached to the roofing material, wherein the interply material includes an adhesive coating on one side. The interply material is attached adjacent to an edge of the roofing material to permit a major portion of the interply material to be folded away from the roofing material for application to a roof. The adhesive is effective to secure the roofing product to the roof without the use of nails or other fasteners. The roofing material may be a roofing shingle or roll roofing, and the interply material is comprised of a water resistant material.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Disclosed herein are photovoltaic building materials and related methods of manufacturing and installing such materials. In one embodiment, a modular roofing structure comprises a photovoltaic shingle panel having a planar lower surface and an upper surface, and a rigid back member having a length the same as or greater than the length of the shingle panel and attached to the planar lower surface of the shingle panel. The roofing structure also includes at least one electrical contact pad on a lower surface of the back member, and at least one electrical conductor electrically coupled to the shingle panel via the lower surface and passing through the back member and out the lower surface. In such embodiments, the electrical conductor is electrically coupled to the at least one contact pad and extends past a front end of the back member sufficient to electrically contact a contact pad on another back member of a separate modular roofing structure couplable to the first.

Abstract: The present invention relates to a heat reflective coated structural article comprising a heat reflective component and a coated structural article component which comprises a substrate having an ionic charge coated with a coating having essentially the same ionic charge. The coating of the coated structural article consists essentially of a filler material and a binder material wherein the binder material bonds the filler material together and to the substrate and wherein the coating does not bleed through the substrate. Nonlimiting examples of the heat reflective component include, elastomeric coatings, aluminum fiber coatings, acrylic and polyurethane coating systems, ceramic coatings insulating paints, metal pigment paints, metal pigment pastes and aluminum flakes. The heat reflective coated structural article of the present invention may be incorporated into commercial roofing products.

Abstract: A composite material comprising a substrate having an ionic charge which is coated with a coating having essentially the same ionic charge and a metallic component adhered on one or both sides of the coated substrate. The coating consists essentially of a filler material comprising clay and a binder material. The substrate is preferably fiberglass, the filler material may further comprise at least one additional filler selected from the group consisting of decabromodiphenyloxide, antimony trioxide, fly ash, charged calcium carbonate, mica, glass microspheres and ceramic microspheres and mixtures thereof and the binder material is preferably acrylic latex. The metallic component is preferably aluminum foil. The composite material has heat insulating and fire resistant characteristics.

Abstract: A composite material comprising at least a first layer which comprises a surfactant component, surfactant-generated microcells, a filler component and a binder component; and a second layer which comprises a metallic component. The composite material may further comprise a substrate to which the first layer is adhered. The composite materials have heat insulating, and fire resistant characteristics and are particularly suited for use in building materials and mattresses.