Abstract: A method and apparatus for applying or dropping granules onto the asphalt coated surface of a moving sheet in shingle manufacturing is disclosed. The method includes sharing each drop between two or more blend rolls with a subsequent blend roll or rolls applying a partial drop directly on top of partial drops already applied by a first blend roll or rolls. High production speeds can be accommodated since each roll can be operated at slower rotation rates and with slower acceleration and deceleration requirements than would be required if the full granule drop were applied during the same time interval with a single blend roll.

Abstract: A machine for dusting a shape with particulate matter, the shape being a profiled roof tile including raised patterns extending in the lengthwise direction thereof, and including raised portions laterally separated from hollow portions by sloped portions, the tile having a predetermined width, and being preferably corrugated, the machine including a dusting element forming a homogeneous linear curtain of particulate matter falling across the width of the tile, the tile travelling longitudinally under the linear curtain. Deflectors of the curtain are arranged above the tile to intercept the particulate matter above the areas at the bottom of the sloped portions and redistribute the intercepted particulate matter towards an intermediate level of each corresponding sloped portion in order for the amount of particulate matter on the surface of the plate ultimately to be substantially homogeneous after a portion of intercepted particulate matter has slid towards the bottom of the sloped portion.

Abstract: A method for controlling a contact angle between a glue and a surface of a substrate during manufacture of microchip packages is disclosed. The method includes applying a glue to a surface of a substrate, and placing an electrode in electrical connection with the glue. A potential difference is applied between the electrode and the substrate. The potential difference is applied across the glue and causes a contact angle between the glue and the surface of the substrate to be altered.

Abstract: An asphalt-based sheet roofing material includes capsules on its upper surface. When struck, as by hailstones, the capsules break to release a film forming fluid that spreads over the surface to heal the damage created by the hailstones.

Abstract: The retention of roofing granules on bituminous roofing products is enhanced by providing an adherent material in the interstices between the exterior surface of the roofing granules and the exposed upper surface of the base sheet.

Abstract: A method of manufacturing roofing shingles is provided. The method includes the step of coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet. The asphalt-coated sheet has at least one prime portion and at least one headlap portion. The thickness of the asphalt-coated sheet is varied by passing the asphalt coated sheet through compression rollers configured to compress the asphalt-coated sheet and form a formed sheet such that the prime portion of the formed sheet has a first thickness and the headlap portion has a second thickness, different from the first thickness. The formed sheet is passed under a film applicator configured to supply a film to the headlap portion thereby forming a filmed sheet. Granules are applied to the filmed sheet to form a granule-covered sheet such that granules do not adhere to the headlap portion. The granule-covered sheet is cut into shingles.

Abstract: A granule applicator for an apparatus and method for applying granules onto an asphalt-coated sheet moving in a machine direction with improved resolution and edge definition of the applied granule patches and blends. One embodiment includes a rotating drum having openings that connect the interior space and an exterior of the rotating member. A granule dispenser is mounted within the interior space of the drum for dispensing granules there. A belt wraps around a major portion of the outside of the drum leaving an uncovered area. As the drum rotates within the belt, the granule openings move between a position closed by the belt and retaining granules by centripetal force and an open position wherein the granules are flung from the drum to a substrate. Doors may be used instead of a belt.

Abstract: A granule applicator for an apparatus and method for applying granules onto an asphalt-coated sheet moving in a machine direction with improved resolution and edge definition of the applied granule patches and blends. In one embodiment a blend drop conveyor has an upper flight urged into a concavity by an outside, third roller. The conveyor is configured to receive granules at a first speed in an area near the convergence of the upper flight and the third roller, and to traject them on a second path at a second speed near the sheet speed of the substrate below. The applicator thus changes the speed and direction of the granules, to cause them to land on the substrate with good edge definition and minimal splatter.

Abstract: A method of manufacturing roofing shingles comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, varying the thickness of the asphalt-coated sheet such that the at least one prime portion of the asphalt-coated sheet has a first thickness and the headlap portion has a second thickness, the thickness of the asphalt-coated sheet being varied by passing the asphalt-coated sheet through a secondary coater to form a granule-covered sheet, and cutting the granule-covered sheet into shingles.

Abstract: A shingle is provided and its method of manufacture, in which granules are applied to an upper surface of a hardenable coating on a layer of shingle-making material, with granules of different pre-selected visual aesthetics provided in different tab areas, separated by mixtures of granules from adjacent tab areas forming intermediate areas, and in which the intermediate areas are removed to yield slots separating adjacent tabs, leaving visually sharp, precise starting and ending delineations for the tabs of a given aesthetic, that can be the same as or different than the aesthetic of an adjacent tab.

Abstract: A method of making a composite roofing material and the resulting material by depositing nail tabs made of a thermoplastic, thermosetting, adhesive or elastomer material, in a liquid state, onto the base substrate of the composite roofing material or onto the saturated or coated roofing material, or onto a transfer surface to be pressed or laminated onto the roofing material. A preferred embodiment transfers the nail tabs onto an engraved transfer impression roll and uses a pressurized applicator to inject the viscous tab material into engraved patterns depressed in raised areas of the impression roll., then deposits the material onto the roofing material. A preferred embodiment also includes the thermoplastic or thermosetting material in a liquid or viscous state hardened or cured by either its exposure to the air or by the use of ultra-violet or visible light.

Abstract: A method of manufacturing roofing shingles including the steps of coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime region, applying alternate granules onto the at least one prime region, applying prime granules over the alternate granules to form a granule-covered sheet, and cutting the granule-covered sheet into shingles.

Abstract: A method of making shingles includes providing a moving asphalt coated sheet having at least an overlay lane and an underlay lane. Blend drops of at least two color blends are discharged onto each lane, wherein at least one of the blend drops discharged onto the overlay lane has a different color blend from the color blends of all the blend drops discharged onto the underlay lane. Background granules are then discharged onto the asphalt coated sheet to form a granule coated sheet, and the excess granules are removed from the granule coated sheet.

Abstract: A method of making shingles includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, and covering the asphalt-coated sheet with granules to form a granule-covered sheet along a longitudinal axis, the granule-covered sheet having a shadow patch thereon, the shadow patch having a first width along the longitudinal axis. The granule-covered sheet is divided into an overlay sheet and an underlay sheet, the shadow patch being on the underlay sheet. A pattern of tabs and cutouts is cut in the overlay sheet, one of the tabs of the pattern being a select tab having a second width along the longitudinal axis, the second width of the select tab being less than the first width of the shadow patches. The relative longitudinal positions of the shadow patch and the select tab are synchronized.

Abstract: An apparatus is provided for the continuous manufacture of shingles, for producing a plurality of laminated shingles.

Abstract: Apparatus for depositing granules onto a substrate includes a hopper for containing granules, the hopper having a discharge slot, and a reciprocating gate mounted for rotation across the slot to open and close the slot. A method of depositing granules onto a moving substrate includes providing a hopper for containing granules, where the hopper has a discharge slot. A gate is moved across the slot to open and close the slot. When the slot is open granules fall from the hopper, and when the slot is closed granules are prevented from falling from the hopper. The method further includes detecting the speed of the substrate, and controlling the extent of opening of the slot by the gate to meter the granules falling from the hopper in response to the speed of the substrate.

Abstract: A roof covering has a back surface and a plurality of glass particles applied as a backdust on the back surface. A method of manufacturing a roof covering includes coating a substrate with an organic-based coating material, and applying a plurality of glass particles as a backdust on the back surface of the coated substrate.

Abstract: A method is provided of continuously producing a plurality of laminated shingles, including the steps of advancing a fiber sheet, waterproofing the sheet, applying granules thereto, cutting and separating the sheet into a plurality of strips which are positioned and adhered to each other to be multi-layered, and then cutting the strips while controlling the placement of longitudinal centerlines of the strips, and cutting the multi-layers so as to form a plurality of shingles.

Abstract: In a method of reducing voids in an asphalt roofing product, an asphalt coating material having voids is contacted with a vacuum in an amount effective to reduce the voids in the coating material. A mat is coated with the coating material to make an asphalt roofing product. The vacuum contacting step occurs prior to the coating step. The vacuum contacting step causes the roofing product to have reduced voids visible on a top surface compared to the same roofing product made with a coating material not contacted with vacuum.

Abstract: A method of making shingles includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, and covering the asphalt-coated sheet with granules to form a granule-covered sheet along a longitudinal axis, the granule-covered sheet having a shadow patch thereon, the shadow patch having a first width along the longitudinal axis. The granule-covered sheet is divided into an overlay sheet and an underlay sheet, the shadow patch being on the underlay sheet. A pattern of tabs and cutouts is cut in the overlay sheet, one of the tabs of the pattern being a select tab having a second width along the longitudinal axis, the second width of the select tab being less than the first width of the shadow patches. The relative longitudinal positions of the shadow patch and the select tab are synchronized.

Abstract: The variegated shingle comprises a shingle layer having front and rear surfaces the front surface including a butt portion and a headlap portion. The shingle layer contains granules on the front surface forming a plurality of horizontal striations providing gradations having color values ranging from light to dark extending between a leading edge of the butt portion and an upper portion thereof. The striations include an upper striation along the upper portion, a lower striation closer to the leading edge, and an intermediate striation between the upper and lower striations. The upper striation is darker in color value than the lower striation, whereas the intermediate striation is no darker in color value than the upper striation and no lighter in color value than the lower striation. The color values of at least one of the upper, lower, and intermediate striations vary across the granule layer.

Abstract: Information as to the location, date and shift of manufacture of roofing shingles is cut into an edge of the shingles as a coded sequence of slits. Preferably, the slit sequence is coded using a binary coding scheme, with a separate binary number group defining each of the shift, the month, the day and the year of manufacture, in addition to plant site identification information. Based on the easily-cut, binary-coded slit sequence, used in conjunction with the plant site identification information, a manufacturer can quickly isolate the time and place of a manufacturing defect. The method of providing a roofing shingle with a coded indication of the shingle's time of manufacture involves arranging a physically-ordered sequence of slit cutting knives, based on a sequence of binary digits, in which a slit cutting knife is provided in the physically-ordered sequence when a corresponding binary digit in the sequence of binary digits is a first value (e.

Abstract: A method for the production of a laminated shingle wherein at least two strips of a continuously advancing sheet are coated with differently colored aggregates of granules. Present among one of the aggregates are a multitude of granules having at least one color and/or hue thereof not present among the granules of the other aggregate or aggregates. The strips are cut from the sheet and laminated one above the other so as to form at least two layers with the differently colored aggregates exposed to view. The difference in coloration creates a pleasing color contrast and accentuates the difference in elevation between the shingle layers.

Abstract: A method is provided for making a shingle by cutting a layer of shingle material to have a headlap area and a tab area, and with a plurality of tabs being present in the tab area, separated by slotted openings. The tab area of the shingle is made to have a predetermined design that has a repeatability in the longitudinal direction, or from one edge of a shingle to another in the right-to-left direction, which repeatability is a function of the length of the shingle between said left and right edges, as well as being a function of the number of tabs in the shingle, with the repeatability being greater or smaller than the length of the shingle in the longitudinal direction. Thereby, a method is provided for producing an ornamental appearance that has a random, natural-looking effect when the shingles are laid up on a roof.

Abstract: Apparatus is provided for making a multi-layer shingle by cutting an anterior layer of shingle material to have a headlap area and a tab area, and with a plurality of tabs being present in the tab area, separated by slotted openings. The tab area of the anterior shingle layer has a predetermined design that has a repeatability in the longitudinal direction, or from one edge of a shingle to another in the right-to-left direction, which repeatability is a function of the length of the shingle between said left and right edges, as well as being a function of the number of tabs in the anterior shingle layer, with the repeatability being smaller or greater than the length of the shingle in the longitudinal direction. Thereby, the apparatus produces an ornamental appearance that has a random, natural-looking effect when the shingles are laid up on a roof.

Abstract: A bitumen-based waterproofing membrane is provided with an improved edge for sealing with a contiguous membrane to provide a membrane system with improved waterproofing characteristics. A bitumen-based reinforced membrane sheet is coated with granular material to protect the membrane sheet from ultraviolet rays. However, a section of the membrane sheet is first covered with a piece of protective tape which prevents any granular material from being deposited on the lateral section of exposed bitumen beneath the tape. The membrane sheets are then cut immediately prior to the tape or at the edge of the granular coating and then rolled up. Accordingly, the lateral section of bitumen which is covered by the protective tape is on the innermost part of the rolled-up membrane sheet. During installation, the tape is removed and the exposed bitumen or selvage section is disposed below an adjacent or contiguous membrane. Heat is then applied for an easy and effective seal between two adjacent membrane sheets.

Abstract: In a method of forming a pattern of granules on an asphalt coated sheet moving in a machine direction, a flow of separate first granules and second granules is discharged onto the sheet. The flow of granules is rotated to form a pattern of first and second granules on the sheet that changes along the machine direction. Another embodiment of the invention provides a method of forming a pattern of granules, in which the flow of granules is oscillated in a direction transverse to the machine direction. The flow of granules can also be discharged intermittently onto the sheet.

Abstract: A method for applying granules to a moving asphalt coated sheet includes providing a nozzle for discharging granules onto a sheet having first and second edges. The nozzle is mounted for movement along a path which traverses the sheet and extends beyond the first and second edges to define first and second extension locations beyond the edges. The nozzle is moved along the path, and the discharge of granules is begun while the nozzle is adjacent or opposite the first extension location, and the discharge of the granules is ended after the nozzle has traversed the asphalt coated sheet and reached the second extension location so that the beginning and ending of the granule discharge do not occur between the first and second edges. The path and the speed of the nozzle can be adjusted so that the deposit of the granules applied to the sheet has a predetermined shape.

Abstract: A method for producing asphalt fibers includes supplying molten asphalt to a rotating asphalt spinner, centrifuging asphalt fibers from the asphalt spinner, and collecting the asphalt fibers. The molten asphalt is supplied to the asphalt spinner at a temperature within the range of from about 270.degree. to about 500.degree. F. Also disclosed is a method for integrating asphalt with reinforcement fibers including the steps of establishing a downwardly moving veil of reinforcement fibers, such as glass fibers, and centrifuging asphalt fibers from a rotating asphalt spinner positioned within the veil of reinforcement fibers to integrate the asphalt with the reinforcement fibers. A method for making an asphalt roofing shingle includes the steps of assembling together a mat of asphalt fibers with a mat of reinforcement fibers, coating the assembled mats to form an asphalt coated sheet, applying granules to the asphalt coated sheet, and cutting the asphalt coated sheet into roofing shingles.

Abstract: A method for making asphalt fibers includes supplying molten asphalt to a rotating asphalt spinner at a temperature between about 270.degree. F. and about 500.degree. F., centrifuging asphalt fibers from the asphalt spinner, and collecting the asphalt fibers. A method for integrating asphalt with reinforcement fibers includes establishing a moving veil of reinforcement fibers, such as glass fibers, and centrifuging asphalt fibers from a rotating asphalt spinner positioned within the veil of reinforcement fibers such that the asphalt is integrated with the reinforcement fibers. A method for making asphalt roofing shingles includes assembling together a mat of asphalt fibers with a mat of reinforcement fibers, coating the assembled mats to form an asphalt coated sheet, applying granules to the asphalt coated sheet, and cutting the asphalt coated sheet into roofing shingles.

Abstract: Volcanic ash is applied to hot asphalt roofing shingles during manufacture to maintain separation and inhibit color transfer between the shingles when stacked. Volcanic ash is separated into a fine particulate component which is a respirable dust and a remainder separating agent component which can be handled without respiratory equipment. After a roofing shingle core material such as an organic film or fiberglass sheet has been dipped into hot asphalt and colored roofing granules have been applied to one side of the hot asphalt-coated core material, the separating agent component is applied by spraying or gravity feed through a perforated plate to the opposite side of the hot asphalt-coated core material.

Abstract: In the manufacture of chemical products, foods, pharmaceuticals and the like, a movable tank (201) mounted on a conveying vehicle (100) movable along conveyance courses (1, 1') between a plurality of stations (11-16) for unit processes such as mixing and reaction is transferred between relative stations by a transferring device provided on the conveying vehicle, to thereby successively perform necessary processes, thus meeting the needs of a multi-product/small-lot production. An automatic connection device is provided for supplying electric power and fluid to the movable tank. Furthermore, when necessary, a traverser device (2) for transferring the movable tank is provided between one conveyance course (1) and another conveyance course (1'). Further, a washing device is provided for washing the movable tank after the completion of the processes.

Abstract: Roofing granules having surfaces treated with an oil and an elastomeric rubber. The elastomeric rubber can be an organic block copolymer having elastomeric and nonelastomeric repeating units. The oil and rubber are applied to the roofing granules' surfaces as a thin film. The thin film of oil and rubber impedes granule staining from oils in asphalt roofing materials, and reduces dust formation during granule handling. Also disclosed is a roofing shingle and a process for making the roofing granule composition.

Abstract: A method of making roofing shingles in several lanes in which, after the asphalt saturated base sheet is covered with a first granule layer, a pattern of asphalt patches is printed on each lane and contrasting color granules are adhered to the patches. Each patch pattern repeats each shingle length but is non-symmetric about the center line of the length of each shingle. When the sheet is cut into shingles, the shingles from each lane have a different patch pattern from the other lanes. The shingles are assembled in bundles containing shingles from at least two lanes and approximately equal numbers of the patch patterns are located on opposite sides of the bundle to make sure the bundle is not tilted. The patch pattern is such that when each shingle is cut into tabs (thirds), at least one and preferably two tabs from each shingle has its center free of patches, enabling the tab to bend over a ridge with less risk of cracking. Preferably no patches are located at the lines where the shingles are cut into tabs.

Abstract: A granule application device for use in making a shingle roofing product is provided. This device includes a sheet having a weather protected headlap area and having a weather exposed butt area which moves continuously from an upstream end to a downstream end. The device includes a blender applicator which dispenses blended butt granules on the sticky, asphalt treated, upper surface of the sheet for covering the butt area only. The device also includes a headlap applicator which dispenses less expensive headlap granules on the headlap area only. The device also includes a recycle applicator, which dispenses recycle granules over the blended granules on the butt area only, and dispenses scrap granules over the headlap area only. The moving sheet is supported on a talc drum and a slate drum near the downstream end, and is supported on a back roll near the upstream end thereof.

Abstract: A rectangular shingle sheet having a butt portion which is longitudinally divided into spaced apart tab segments and an undivided headlap portion which is 1.3 to 1.5 times higher than the outward extensions of said tab segments in the butt portion; the butt portion and headlap portion carrying an asphaltic backing of varying thickness wherein the upper area of the headlap portion which is of a height approximately equal to that of the butt portion is coated with an asphaltic backing of between about 5 and about 15 mils thickness and the remaining lower area of the headlap portion and the entire butt portion is uniformly coated with an asphaltic backing of between about 20 and about 100 mils thickness. In one embodiment, the shingle is a composite roofing shingle comprising a shingle sheet having a butt portion which is longitudinally divided into spaced apart tab segments, and a separate elongated strip underlying the tab segments which fills the space between the tabs.

Abstract: A lightweight asphalt roofing product wherein the asphalt-based coating has a specific gravity less than 1.0. A lightweight filler is used which has an effective specific gravity in the range of 0.10-0.50 and is present in the coating in the range of 3%-25% by weight of the filled coating. In a preferred embodiment, the filler particles have hollow, gas filled inclusions, and comprise expanded perlite particles or expanded permicite particles.

Abstract: An improved apparatus for manufacturing roofing shingles having multiple ply appearance, in which an elongated strip of a dry organic or mineral material previously saturated in an asphalt tank and with at least one uniform longitudinally continuous strip of a first coating of granules is fed into the apparatus. The apparatus automatically and repeatedly applies spaced apart bands of varying widths of an adhesive material onto the first coating of granules. A second coating of granules is then automatically applied by the improved apparatus to the asphaltic bands. The application of the adhesive bands and the subsequent granule distribution are synchronized so that the granules are distributed only upon the bands of adhesive.

Abstract: The present invention relates to the field of roof coverings, specifically laminated roof shingles formed of mineral granule covered, asphalt saturated felt material. The disclosed shingle when combined with other shingles on a roof deck simulates a tile covered roof. This simulation is accomplished by making a generally rectangular laminated shingle having a headlap portion and an exposed butt portion made up of a regular uniform series of substantially identically shaped tabs with spaces therebetween defining exposed portions of an underlay member attached to the lower surface of the tabs. The lower edges of these tabs and spaces define a butt edge having a generally continuously curving sinuous contour. The tabs have generally straight sides which taper from this butt edge to the lower edge of the headlap portion. A plurality of such shingles are placed on a roof deck such that the tabs are aligned vertically up the roof deck and the spaces between these tabs are also vertically aligned.

Abstract: A unique method for applying a lightweight cementitious coating to either existing or new roof surfaces. The invention relates to the method of preparing the coating mixture and its manner of application.