Abstract: Some embodiments of the present disclosure relate to a roofing system. In some embodiments, the roofing system includes a roofing membrane, which may include a cap, a scrim, and a core. In some embodiments, the roofing system may also include an adhesive film, which may include a first adhesive layer adhered to the roofing membrane, a second adhesive layer configured to adhere the roofing membrane to a roofing substrate, and a barrier layer positioned between the first and second adhesive layers. Methods of manufacturing roofing systems are also disclosed.

Abstract: A process for in-line extrusion of polymeric coatings onto roofing shingles during manufacturing includes moving a web of shingle substrate material in a downstream direction and extruding a liquefied coating of polymeric material onto at least one surface of the moving web to form a thin film. The liquefied coating may be a molten polymeric material that forms a thin film on a back surface of the shingle material to prevent sticking and eliminate the need for a traditional back dusting with material such as powdered stone. The polymeric film further may be applied to the substrate material in lieu of a saturation coating of asphalt, thus reducing cost and weight while providing a comparable moisture barrier and a lighter more flexible shingle.

Abstract: This invention, in embodiments, relates to a device and a method of attaching a roofing membrane to a building surface that prevents and/or reduces overspray of adhesive onto a welding seam area. The device includes an insertion mechanism configured to hold a roofing membrane as the roofing membrane is being attached to a building surface via an adhesive, and an extension frame attached to the insertion mechanism, the extension frame including a channel that is configured to support and to hold at least one board, to thereby reduce the adhesive from spraying onto a welding seam area as the roofing membrane is being applied to the building surface.

Abstract: Exemplary embodiments of a thermoplastic polyolefin membrane are provided. The colored TPO membrane can have a cap layer having a top color layer and a white sub-layer having a solar reflectance underneath the top color layer, and a core layer underneath the cap layer. The colored TPO roofing membrane can have a reinforcing polyester scrim between the cap layer and the core layer. The white sub-layer can be made up of one or more layers.

Abstract: Systems and methods are described herein for manufacturing and using roofing membranes that are faster and easier to install than conventional adhesive-only membrane materials. In some embodiments, membrane materials are surface treated using a plasma flow, e.g., a blown-arc plasma flow, atmospheric plasma, corona plasma, or from portable plasma units, generated by passing a compressed plasma-generating gas through an electrical current to form the plasma-treated roofing membrane. The plasma treatments described herein may be applied as part of the manufacturing process, or in-situ at the site of roof installation. In some embodiments, membrane materials have surface chemistries, roughnesses and other surface characteristics that yield desired adhesion properties.

Abstract: Building materials such as structural panels, beams, roof decking, and flooring panels, are packaged within a protective layer including a sublayer of a polymeric material that can be applied at the factory. The protective layer protects the underlying building materials from exposure to weather and potential damage due to handling during shipping, at a job site, and which can be left in place during construction, thus eliminating the need for temporary protective measures covering the building materials. The protective layer may have additional properties such as breathability, fire resistance, and sound absorption. The protective layer also may provide an underlayment such as for flooring and roofing.

Abstract: Non-limiting embodiments of the present disclosure relate to a method comprising: obtaining asphalt shingle waste (ASW) and performing grinding, screening, and separating steps on the ASW. In some embodiments, granules are removed from the ASW. In some embodiments, the method transforms ASW into ASW powder. In some embodiments, the ASW powder is formed into a plurality of briquettes. In some embodiments, at least one of: the ASW powder, the plurality of briquettes, or any combination thereof is fed into a mixing process that results in an ASW powder filled coating. In some embodiments, the ASW powder is formed into an adhesive composition.

Abstract: Some embodiments of the present disclosure relate to roofing systems including a substrate and adhesive formulations that are free of asphalt or substantially free of asphalt. Some embodiments of the present disclosure relate to methods of making one or more adhesive formulations that are free of asphalt or substantially free of asphalt. Some embodiments of the present disclosure relate to systems utilizing one or more adhesive formulations that are free of asphalt or substantially free of asphalt.

Abstract: A photovoltaic module incorporates a lamination including a back-sheet, an array of solar cells supported on the back-sheet, and a transparent protective covering over the array of solar cells. The solar cells are arranged in offset or staggered patterns on the back-sheet to present a more random and less rigid industrial appearance to an observer. In some cases, cleaved solar cell segments are arranged into groups that are staggered on the back-sheet. This allows for finer control of the net voltage produced by a module. In other embodiments, full single wafer solar cells are arranged into larger groups, which themselves are staggered on the back-sheet. In either case, the result is a photovoltaic module with an appearance that is more organic and acceptable to homeowners and architects than traditional modules having cells arranged in rigid aligned rows and columns.

Abstract: Roofing shingles are disclosed that are capable of self-adhering to a roof deck or underlayment and/or other roofing shingles and that require few or no mechanical fasteners to remain attached to the roof. By appropriate positioning of sealant lines on the shingle, direct adhesion between the shingle and the roof deck or underlayment and/or other roofing shingles can be achieved. If the shingle is laminated, the layers may be mechanically attached with indentations in the common bond area. The nail zone of the shingle may be visually indicated with fines and/or one or more paint lines. A roofing system comprising a plurality of courses of the shingles is also disclosed.

Abstract: Shingles have self-seal strips with features that include sealant dashes or dots separated by drainage gaps. The self-seal strips are registered with each shingle so that the features are positioned at the same locations on each shingle. A method of making such shingles includes synchronizing the rotation of sealant applicator wheels with the shingle chop cutter so that cuts are made at repeated designated locations along the applied self-seal strips.

Abstract: Some embodiments of the present disclosure relate roofing membranes that may include at least one first layer including a first plurality of protrusions; at least one second layer including a second plurality of protrusions; and a plurality of inner regions disposed between a raised protrusion of the first plurality of protrusions and a raised protrusion of the second plurality of protrusions. Some embodiments of the present disclosure relate to methods of forming roofing membranes. The methods may include applying a blowable ink onto at least one porous layer; sandwiching the at least one porous layer between the at least one first layer and the at least one second layer; and expanding the blowable ink, so as to form the first plurality of protrusions, the second plurality of protrusions, and the plurality of inner regions.

Abstract: Some embodiments of the present disclosure relate to an article comprising a reinforced glass mat. In some embodiments, the reinforced glass mat includes a glass mat and a reinforcement material. In some embodiments, the glass mat includes a web of glass fibers. In some embodiments, the reinforcement material is embedded into the web of glass fibers of the glass mat. In some embodiments, the reinforced glass mat includes a sufficient amount of the reinforcement material, so as to result in a nail shank shear resistance of 13 lbs to 17 lbs, when the article is tested according to ASTM 1761 at 140° F. Methods of making the article, specific embodiments of the reinforcement material in the form of a polymeric binder, and methods of forming a roofing shingle from the article are also disclosed.

Abstract: Nail sealable materials comprising a matrix material and bentonite embedded within the matrix material are described herein in accordance with non-limiting embodiments of the present disclosure. In some embodiments, the nail sealable material comprises a sufficient amount of bentonite, such that the nail sealable material passes ASTM D1970 at a specified nail sealable material test thickness. Some embodiments relate to systems and methods utilizing the nail sealable materials described herein.

Abstract: In some embodiments, the present disclosure provides systems and methods enabling unmanned vehicle navigation and delivery including an integrated roofing accessory integrated into a roof, the integrated roofing accessory including at least one antenna and a computing module in communication with the at least one antenna, where the computing module, when software is executed, is configured to transmit, via the at least one antenna: electronic operating instructions to at least one unmanned vehicle, and network messages related to the at least one unmanned vehicle to at least one additional integrated roofing accessory. A landing member is on the roof and the electronic operating instructions comprise: at least one landing instruction configured to cause the at least one unmanned vehicle to land on the landing member, and at least one take-off instruction configured to cause the at least one unmanned vehicle to take off from the landing member.

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: A water barrier system to protect a roof surface from environmental conditions is disclosed. In one embodiment, the water barrier system includes an underlayment layer and a liquid applied coating. In use, the underlayment is coupled to the roof surface. Thereafter, the liquid coating is applied to the underlayment to form a barrier layer. The underlayment may be manufactured from a porous material so that the liquid applied coating is at least partially absorbed by the porous underlayment. In this manner, direct application of the liquid coating to the roof surface is eliminated. In one embodiment, the underlayment may be provided with a load bearing component/layer and a coating absorbing component/layer. For flat roof applications, the load bearing component/layer may be provided with increased rigidity for dimensional and installation stability.

Abstract: A multi-layer cap shingle for installation along a ridge, hip, or rake of a roof includes a forward exposure area and a rear headlap area. The multi-layer cap shingle includes at least two layers of shingle material, a top layer and a bottom layer each having opposed edges. The layers are bonded together with patches of lamination adhesive adjacent their opposed edges. The bottom layer is configured with a deformation-absorbing mechanism such as a pair of slots extending from a forward edge reawardly inboard of the lamination adhesive patches. When the multi-layer cap shingle is bent over a roof ridge, the slots of the bottom layer of shingle material narrow in width to account for the fact that the bottom layer must bend around an arc of slightly smaller radius than the top layer of shingle material.