Abstract: Some embodiments relate to asphalt shingle waste coatings in roofing shingles of roofing systems. A roofing system comprises a plurality of roofing shingles. The plurality of roofing shingles, when installed on a roof substrate, comprises exposed surfaces and unexposed surfaces. The plurality of roofing shingles comprises asphalt shingle waste coatings on or only on at least one of the unexposed surfaces. The plurality of roofing shingles comprises asphalt coatings on or only on at least one of the exposed surfaces.

Abstract: Plant for making decorations on a bituminous membrane including a feed device configured to feed the bituminous membrane at a determinate speed in a direction, and at least two depositing apparatuses disposed one in series with the other in the direction and configured to deposit solid particles on the bituminous membrane according to respective patterns in order to obtain respective decorations on the bituminous membrane. The depositing apparatuses each includes a transfer member configured to receive, support and transfer the solid particles from a respective feed device, to the surface to be enhanced of the bituminous membrane.

Abstract: A lightweight thermoplastic polyolefin roofing underlayment with superior tear strength is disclosed having a printed upper surface simulating the appearance of a finished roof. The underlayment is reinforced with a woven polypropylene scrim. Anti-skid materials can be incorporated into the body of the underlayment.

Abstract: A high speed granule delivery system and method for dispensing granules in intermittent patterns onto a moving asphalt coated substrate includes a granule hopper and a rotationally indexable pocket wheel in the bottom of the hopper. A series of pockets are formed in the circumference of the wheel and separated by raised lands. A seal on the bottom of the hopper seals against the raised lands as the pockets are filled with granules during rotation of the pocket wheel through the hopper. As each pocket is indexed beyond the seal, it is exposed to the moving asphalt coated substrate below and its granules fall onto the substrate to be embedded in the hot tacky asphalt. The speed at which the wheel is indexed is coordinated with the speed of the asphalt coated substrate to form well defined patterns of granules at high production rates.

Abstract: A method of manufacturing a granule coated asphaltic article comprising the steps of applying liquid asphalt to a reinforcing sheet to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface; bending the asphaltic sheet to form an arcuate top surface of the sheet; and applying a coating of granules over the arcuate top surface of the asphaltic sheet.

Abstract: A high speed granule delivery system and method is disclosed for dispensing granules in intermittent patterns onto a moving asphalt coated substrate in the manufacture of roofing shingles. The system includes a granule hopper and a rotationally indexable pocket wheel in the bottom of the hopper. A series of pockets are formed in the circumference of the wheel and the pockets are separated by raised lands. A seal on the bottom of the hopper seals against the raised lands as the wheel is indexed. In use, the pockets of the pocket wheel drive through and are filled with granules in the bottom of the hopper. As each pocket is indexed beyond the seal, it is exposed to the moving asphalt coated substrate below and its granules fall onto the substrate to be embedded in the hot tacky asphalt.

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 high speed granule delivery system and method is disclosed for dispensing granules in intermittent patterns onto a moving asphalt coated strip in the manufacture of roofing shingles. The system includes a granule hopper and a rotationally indexable pocket wheel in the bottom of the hopper. A series of pockets are formed in the circumference of the wheel and the pockets are separated by raised lands. A seal on the bottom of the hopper seals against the raised lands as the wheel is indexed. In use, the pockets of the pocket wheel drive through and are filled with granules in the bottom of the hopper. As each pocket is indexed beyond the seal, it is exposed to the moving asphalt coated strip below and its granules fall onto the strip to be embedded in the hot tacky asphalt.

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: A roofing shingle has a shingle body with at least a top layer having a buttlap portion with a butt edge and a headlap portion. An exposure zone extends from the butt edge toward the headlap portion is configured to be exposed to the environment when the roofing shingle is installed on a roof. A shadow formation may be located in the exposure zone of the top layer. The shadow formation and the exposure zone differ from each other in at least one aspect, such as color. The top layer may be substantially rectangular and have no tabs formed along the butt edge. A thickness of the exposure zone and a thickness of the shadow formation may be substantially identical. The shadow formation may be a simulated cut out, slit or slot.

Abstract: A roofing shingle comprising a base mat having a tab portion covered with granules and a headlap portion covered with a mask or film layer. An asphalt-based coating is applied to at least a top surface of the base mat. The film layer is adhered to the asphalt-based coating applied to the headlap portion and the granules are adhered to the asphalt-based coating applied to the tab portion. The film layer is adapted for preventing granules from adhering to the headlap portion of the base mat and, as such, the headlap portion may be substantially free from any granules adhered thereto. A method for manufacturing a roofing shingle is also provided wherein granules that are not adhered to the tab portion of one shingle may be collected and reapplied the tab portion of another shingle.

Abstract: According to one embodiment, a method for pressing roofing granules into a roofing membrane may include providing a roofing membrane and applying roofing granules atop a surface of the membrane. The method may also include adjusting a position of a second roller relative to a first roller so as to vary an amount of contact between the membrane and the first roller and pressing the roofing granules into the membrane via the first roller. In some embodiments, a line speed of the membrane may be determined and a contact value may be calculated based on the line speed of the membrane. The contact value may represent an effective amount of contact between the membrane and the first roller. The position of the second roller may be adjusted so that the amount of contact between the membrane and the first roller corresponds to the effective amount of contact.

Abstract: A high speed granule delivery system and method is disclosed for dispensing granules in intermittent patterns onto a moving asphalt coated strip in the manufacture of roofing shingles. The system includes a granule hopper and a rotationally indexable pocket wheel in the bottom of the hopper. A series of pockets are formed in the circumference of the wheel and the pockets are separated by raised lands. A seal on the bottom of the hopper seals against the raised lands as the wheel is indexed. In use, the pockets of the pocket wheel drive through and are filled with granules in the bottom of the hopper. As each pocket is indexed beyond the seal, it is exposed to the moving asphalt coated strip below and its granules fall onto the strip to be embedded in the hot tacky asphalt. Well defined patterns of granules are possible at high production rates.

Abstract: A method of manufacturing a granule coated asphaltic article comprising the steps of applying liquid asphalt to a reinforcing sheet to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface; bending the asphaltic sheet to form an arcuate top surface of the sheet; and applying a coating of granules over the arcuate top surface of the asphaltic sheet.

Abstract: A roofing product has a substrate having a binder layer and roofing granules on a majority of the binder layer, such that an exposed portion of the binder layer does not have the roofing granules. In addition, particles may be located on the exposed portion of the binder layer. The particles are smaller in size than the roofing granules, and the reflective particles have a solar reflectance of greater than 10%.

Abstract: A shingle, a method of making it, and a roof embodying the shingle is provided, in which an exterior surface of the shingle is provided with an attached reinforcement layer through which fasteners may be applied when the shingle is applied to a roof.

Abstract: A bio-based adhesive and method of making the adhesive replaces or serves as additives for asphalt, sealant, and polymers such as styrene-butadiene-styrene and atactic polypropylene in the manufacture of building or paving materials. The method includes steps of forming a mixture of oil comprising fatty acids group and optionally a powdered material; maintaining the oil-to-powdered-material weight ratio in the mixture between 1 to 0.00001 and 1 to 20; heating the mixture to a reaction temperature greater than 55 degrees Centigrade; maintaining the reaction temperature until the oil is polymerized; and, injecting air into the mixture while polymerizing the oil. The adhesive of this method comprises a renewable polymer and the powdered material.

Abstract: A method of manufacturing a granule coated asphaltic article is disclosed. The method includes applying molten asphalt to a reinforcement to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface. Next, the asphaltic sheet is bent to form an arcuated top surface of the sheet. The method concludes by applying a plurality of granules to the arcuated top surface of the asphaltic sheet.

Abstract: A roofing product and method includes coating a substrate with bitumen to yield a bitumen coated substrate having an exposure zone. First granules are adhered to the exposure zone to yield a first granule coating. The first granules have a solar reflectance greater than 35. An adhesive is adhered to at least a portion of the first granule coating. An open portion of the first granule coating that is free of the adhesive is maintained. An overlay of non-white second granules is adhered to the adhesive, such that the overlay of second granules and the adhesive provide a raised structure above a plane of the first granule coating.

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 roofing and/or siding system having an improved average resulting reflectivity. The roofing and/or siding system is at least partially coated with a plurality of granules. At least one layer of paint is applied to the roofing and/or siding system to increase the resulting reflectivity of the roofing and/or siding system.

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: An adhesive product and method of making the product replaces asphalt in the manufacture of roofing shingles. The method comprises steps of forming a mixture of oil comprising fatty acids and a powdered catalyst operable to catalyze the polymerization of the oil; maintaining the oil to powdered catalyst weight ratio in the mixture between 1 to 0.01 and 1 to 4.9; heating the mixture to a reaction temperature greater than 100 degrees Centigrade; maintaining the reaction temperature for at least five minutes; and, injecting air into the mixture while maintaining the reaction temperature. In making a roofing shingle, the method includes additional steps of: applying the heated mixture to a fiberglass mat sheet from an upstream roll to form a tacky coated strip; and, adding a layer of granules to the tacky coated strip. The adhesive material of this method comprises polymerized oil and the powdered catalyst.

Abstract: A system for manufacturing a granule covered roofing shingle includes establishing at least two sources of granules. A standardized process for manufacturing granules having a standardized appearance is then established, wherein a color of the granules from one of the sources of granules is substantially identical to the color of the granules from the others of the sources of granules, thereby defining at least one standardized granule color. Granules of the standardized granule color are then manufactured according to the standardized process. The manufactured granules are transported to at least one shingle manufacturing facility, and granule covered roofing shingles are then manufactured using the manufactured granules of the standardized granule color.

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 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 compression rollers, applying granules onto the asphalt-coated sheet to form a granule-covered sheet, and cutting the granule-covered sheet into shingles.

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 roofing shingle has low density granules adhered to at least a headlap region on a front surface of the roof shingle.

Abstract: An asphalt-based roofing material includes a coating having a top portion containing a mixture of asphalt and igneous and/or metamorphic rock particles, while the mat portion of the coating contains a mixture of asphalt and a filler which contains less than 10% igneous and/or metamorphic rock particles. In other embodiments, the top portion but not the bottom portion of the coating meets or exceeds a pliability standard, passes a weathering performance test, or has a high solar reflectance. In another embodiment relating to a laminated roofing material, the top portion but not the bottom portion has viscoelastic properties effective to prevent the coating from sticking to an adjacent shingle in a bundle. The invention also relates to a continuous process of applying first and second coatings to a mat for manufacturing a roofing material.

Abstract: Skid-resistant moisture barriers of the invention, such as house wrapping, waterproofing membranes, and roofing underlayrnents, have a carrier sheet with polymer nodules deposited thereon through a rotating screen roll or by transfer means such as a gravure roll. Precise coating levels and polymer distribution can be achieved more easily when compared with prior art coating and embossing methods.

Abstract: A roofing or siding system having an improved average resulting reflectivity. The roofing and/or siding system is at least partially coated with a plurality of granules. At least one layer of paint is applied to the roofing and/or siding system to increase the resulting reflectivity of the roofing and/or siding system.

Abstract: A method for depositing granules (48) onto a substrate (14) comprises providing a hopper (36) for granules with a discharge slot (46), moving a gate (50) across the slot to open and close the slot so that when the slot is open granules fall from the hopper and when the slot is closed granules are prevented from falling from the hopper, and 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 method of making algae-resistant shingles in which the algae-inhibiting material, usually a copper compound, is applied only to larger granules, instead of being applied to a full size range of granules. Use of the larger granules only, as algae-resistant granules, significantly increases the percentage of surface area of algae-resistant granules for releasing algae-inhibiting material and also reduces the material consumption of the algae-inhibiting material during production of the algae-resistant granules, thus substantially reducing cost.

Abstract: A method of coating highly reflective granules on an adhering material of a roofing or siding material to form a roofing or siding material having an average resulting reflectivity on an upper surface of at least about 45%. The method includes the selecting of highly reflective granules and applying the highly reflective granules on an adhering material until over about 95% of a top surface of the adhering material is covered by the granules.

Abstract: A fire resistant, self-adhesive rolled roofing membrane is used on low sloped roofs for insulating a surface from weather. The roofing membrane includes an asphalt-saturated fibrous material having a roofing surface area, for example, roofing granules on a portion of the top surface and a clean surface area on another portion of the top surface. The roofing membrane includes an adhesive surface area on a portion of the bottom surface opposite the roofing surface area and a parting agent covered surface area on another portion of the bottom surface generally opposite the clean surface area to prevent adhering to the clean surface area when rolled. The adhesive surface area includes a layer of self-adhesive material, such as rubberized asphalt, capable of adhering to the clean surface area when strips of the roofing membrane are overlapped. The adhesive surface area is covered with a release backing to prevent adherence to the roofing surface area.

Abstract: A method of producing asphalt strip shingles includes continuously coating a substrate with asphalt to form an asphalt coated sheet, moving the asphalt coated sheet in a machine direction, depositing blend drops of blend drop granules onto the asphalt coated sheet from a blender, providing a signal indicative of the presence of the blend drops at a location downstream from the blender, sensing the color of the blend drops at the downstream location with a sensor, comparing the sensed color of the blend drops with a reference color, and providing a signal indicative of the comparison.

Abstract: An asphalt-based roofing material includes a substrate coated with an asphalt coating, a protective coating adhered to the upper surface of the asphalt coating, a layer of granules adhered to the protective coating, and a web bonded to the lower region of the asphalt coating. A method of manufacturing a roofing material includes coating a substrate with an asphalt coating, applying a protective coating to the upper surface of the asphalt coating, applying a layer of granules to the protective coating, and applying a web to the lower region of the asphalt coating.

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: A method of applying blend drop granules to an asphalt coated sheet includes moving an asphalt coated sheet in a machine direction, depositing a blend drop of granules on a blend drop conveyor that is moving at a first speed, changing the speed of the blend drop conveyor to a second speed that is closer to the speed of the moving asphalt coated sheet than is the first speed, and releasing the blend drop from the blend drop conveyor for contact with the asphalt coated sheet.

Abstract: The method of depositing granules in a frame pattern includes moving an asphalt-coated web and depositing successive granule blend drops on the web. The first blend drop has a first color and forms a first blend drop pattern defining an inner region. The second blend drop has a second color and forms a second blend drop pattern sized to fit within the inner region of the first blend drop such that the first blend drop frames the second blend drop. A third blend drop having a different third color or the same as the first color is deposited such that the third blend drop adheres to an intermediate region between the first and second blend drops. The system includes a mechanism for moving the web and an asphalt coater for coating the web with asphalt. First and second media applicators are used to deposit the first and second blend drops in the respective first and second blend drop patterns.

Abstract: This invention relates to a method for embedding a multiplicity of discrete masses of material in a resinous coating on a sheet of metal in a coil coating system. The sheet is coated, the masses are embedded in the wet resinous coating, and the coating is dried in a one-pass system. The resinous coating and the embedded masses are preferably resistant to ultra-violet radiation. The wet resinous coating, therefore, is preferably a liquid fluorocarbon resin. The discrete masses comprise pigmented particulate minerals and resins in the form of granules, beads, vesiculated beads, pellets, flakes, platelets, cylinders, coating powders, and coating powder precursor chips. The minerals include glass, quartz, mica, pebbles, and ceramics. The particulate resins include polyesters, acrylics, nylons, polyurethanes, polycarbonates, solid fluorocarbon resins, and solid mixtures of a fluorocarbon resin and an acrylate or methacrylate polymer or copolymer.

Abstract: A laminated shingle has a rendered shadow design when placed with other similar shingles on a roof deck. The laminated shingle includes an overlay member and an underlay member fixedly attached to each other. The overlay member includes an upper or headlap portion and a lower or exposed butt portion with one or more tabs separated by cutouts. The underlay member is coated with a layer of relatively dark granules to form vertically and horizontally-oriented shading areas. In one embodiment, one or both vertical edges of each tab are generally parallel to the vertically-oriented longitudinal axis of the vertically-oriented shading area to expose a portion of the shading area. In another embodiment, the width of each tab is randomly selected and the width of the vertically-oriented shading area is a function of the width of the adjacent tab. In yet another embodiment, the intensity of the shading areas can increase from the bottom to the top of each cutout.

Abstract: A method of producing asphalt strip shingles includes continuously coating a substrate with asphalt to form an asphalt coated sheet, moving the asphalt coated sheet in a machine direction, depositing blend drops of blend drop granules onto the asphalt coated sheet from a blender, providing a signal indicative of the presence of the blend drops at a location downstream from the blender, sensing the color of the blend drops at the downstream location with a sensor, comparing the sensed color of the blend drops with a reference color, and providing a signal indicative of the comparison.

Abstract: A method of applying blend drop granules to an asphalt coated sheet includes moving an asphalt coated sheet in a machine direction, generating vertically moving blend drops of granules and directing the vertically moving blend drops of granules into contact with a curved conveyor. The blend drops are moved along the curved conveyor to change the direction of the blend drops of granules to a generally horizontal orientation in the machine direction. The blend drops are released from the curved conveyor for contact with the asphalt coated sheet.

Abstract: An asphalt-based roofing material includes a substrate coated with an asphalt coating, a protective coating adhered to the upper surface of the asphalt coating, a layer of granules adhered to the protective coating, and a web bonded to the lower region of the asphalt coating. A method of manufacturing a roofing material includes coating a substrate with an asphalt coating, applying a protective coating to the upper surface of the asphalt coating, applying a layer of granules to the protective coating, and applying a web to the lower region of the asphalt coating.

Abstract: Apparatus and process for coating a continuously advancing web with a dry or wet coating material on a conveyor belt. The apparatus having a hopper which contains an agitator, a brush and a knurled roll to accurately dispense the coating material to an applicator which is positioned on a carousel. By rotating the carousel, the coating in the form of stripes, bars or a uniform layer can be varied at angles 0° to 90° on the continuously advancing web.

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: 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: A method of constructing a resilient surface layer of particles bound together and to a base surface comprises uniformly dropping dry rubber particles from a moving apparatus and spraying the particles with a liquid, water based, latex binder as the particles are dropping, the apparatus comprises a movable vehicle with a particulate spreading assembly comprising a hopper with a controlled orifice, and a spray system with an array of nozzles directed to intersect the path of the particles after leaving the hopper and before the particles reach the base surface.