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 shingle is formed with a substrate saturated with asphalt, an asphalt coating on the saturated substrate, and a top film bonded to the surface of the asphalt coating covering at least a portion of the shingle to be exposed when installed. The top film may be configured to mimic the appearance of traditional clay granules on the shingle or another shingle surface. More specifically, the top film is printed or coated with an image that mimics the appearance of a clay granule bed and is embossed, pressed, or molded to mimic the texture of a clay granule bed. The top film is UV resistant to protect the asphalt below from deterioration. An anti-stick film may be bonded to the back of the shingle to prevent shingles from sticking together when stacked into a bundle.

Abstract: This invention provides for a method for producing polymer modified asphalt using base asphalt (bitumen) blended with partially air blown (“puffed”) asphalt which is further modified with polymers and additives to attain desired properties for industrial applications. The partially blown or blown asphalt is oxidized to a target softening point to suit the application. In another embodiment, the base asphalt is blended with hard PEN asphalt (“Zero PEN Asphalt”) which is further modified with polymers and additives to attain desired properties. By using the partially oxidized asphalt or blending the base asphalt with partially oxidized asphalt or hard PEN asphalt, the amount of polymers and additives needed to achieve desired properties and performance are significantly reduced. This technique can be used to attain polymer modified asphalt having a highly desirable combination of characteristics not otherwise attainable using the base asphalt.

Abstract: The present disclosure relates, according to some embodiments, to roll lifting assemblies, systems, and methods for lifting, handling, and/or maneuvering rolled material. According to some embodiments, a roll lifting system may be configured to move a single roll and/or to concurrently move two or more rolls. For example, a roll lifting system may comprise a translocation apparatus and/or a lift assembly.

Abstract: It has been found that numerous benefits can be realized by air blowing asphalt in the presence of at least one highly saturated polymer, such as polyisobutylene, and a reactive polymer having glycidyl groups, such as an ethylene-glycidyl-acrylate. This allows for asphalt streams which would typically not be commercially viable for blowing into industrial asphalt that can be used in roofing products and a wide array of other applications. For instance, this technique can be used to air blow currently available paving grade asphalts into industrial asphalt for roofing products. Other potential benefits include shorter processing time (air blowing time), reduced emissions, and blown coatings with improved weatherability. In one embodiment of this invention asphalt is only partially air blown before adding the polymer to attain a product having desired characteristics for specific applications.

Abstract: It has been discovered that the efficiency of asphalt blow stills can be improved by sectionalizing the blow still with perforated plates at various heights within the blow still. The perforated plates which contain a multitude of holes act to reduce air bubble size and improve the dispersion of the air bubbles throughout the asphalt flux. This increases the total surface area per unit volume of the air bubbles and promotes a faster processing time. The perforated plates also increase the contact time between the air bubbles and the asphalt flux which further results in improved efficiency and reduced blow times. This is beneficial because faster processing times can be achieved resulting in more efficient use of equipment, higher levels of productivity, lower energy requirements, cost savings, reduce blow loss, and reduced thermal history to which the asphalt is exposed.

Abstract: A solar panel array comprises a first plurality of solar panels arranged side-by-side in a first course and a second plurality of solar panels arranged side-by-side in a second course, the second course partially overlapping the first course. Electrical energy produced by each solar panel of the array is aggregated with the electrical energy produced by the other solar panels of the array without physical electrical contacts between the solar panels. In one embodiment, contactless inductive couplers are used to couple the electrical energies of the panels together.

Abstract: Disclosed herein are thermoplastic olefin (TPO) membranes with enhanced thermal resistance. In an embodiment, the disclosed may include a cap layer, a core layer, and a scrim layer disposed therebetween. The cap layer may be formulated with TPO resins and a UV stabilizer package comprising ultrafine Ti02. The UV stabilizer package may further comprise various other additives, including a UV stabilizer, an antioxidant, a process or thermal stabilizer, and/or a UV absorber.

Abstract: A roofing material is provided having an asphalt-coated mat or felt made up of or in combinations of fiberglass, polyester, nylon, cotton, cellulosic fibers or materials, polyethylene, polypropylene, co-polymers, melamine, phenolic, acrylics, polycarbonate, carbon fiber, clay, metallic in woven, non-woven, strands or sheets, styrene compounds, rubber, silk, leather, or wool in a woven, non-woven, or solid form. The surfacing materials can be made up of or in combination minerals, plastic particles or film, metal particles or film, cement particles, clay particles, paints, coatings, glass, ceramics, wood, wood fiber, or composite materials.

Abstract: A self-sealing mounting bracket includes an outer shell that defines at least one downwardly facing chamber. A plunger is located in the downwardly facing chamber and is slidable within the chamber. The chamber is filled with sealant either at the manufacturing facility or in the field. Larger openings are formed in the top of the outer shell that align with and provide access to bolt holes in the top of the plunger. Smaller openings in the top of the outer shell are for attaching the shell to a roof with lag bolts. The mounting bracket is located on a shingled roof and lag bolts are inserted through the larger openings and threaded into the roof deck. The heads of these lag bolts pass through the larger openings and engage the plungers to press the plungers down in their chambers. This, in turn, compresses, squeezes, and extrudes sealant between the mounting bracket and the roof below forming a water tight seal.

Abstract: In an exemplary embodiment, a shingle manufacturing system comprises an entry pull roll for providing a substantially continuous sheet comprising shingle material, an adhesive applicator for applying a laminating adhesive to a surface of the sheet, and a cutting station for cutting the sheet, now carrying the laminating adhesive, into at least three longitudinal pieces.

Abstract: A roofing material is provided having an asphalt-coated mat or felt made up of or in combinations of fiberglass, polyester, nylon, cotton, cellulosic fibers or materials, polyethylene, polypropylene, co-polymers, melamine, phenolic, acrylics, polycarbonate, carbon fiber, clay, metallic in woven, non-woven, strands or sheets, styrene compounds, rubber, silk, leather, or wool in a woven, non-woven, or solid form. The surfacing materials can be made up of or in combination minerals, plastic particles or film, metal particles or film, cement particles, clay particles, paints, coatings, glass, ceramics, wood, wood fiber, or composite materials.

Abstract: An apparatus is disclosed for applying a strip of sealant to a web of roofing shingle stock as the web moves along a processing path. The apparatus includes an applicator wheel disposed on one side of the processing path and having a peripheral surface. The applicator wheel is rotatably mounted and oriented such that rotation of the applicator wheel moves the peripheral surface of the applicator wheel toward, adjacent to, and then away from the moving web of shingle stock. A nozzle preferably in the form of a slot die is disposed adjacent to the peripheral surface of the applicator wheel. A source of sealant is supplied and a delivery system is configured to deliver the sealant from the source of the sealant to the slot die under a predetermined pressure. The slot die and delivery system are configured to project a stream of sealant toward and onto the peripheral surface of the applicator wheel at a predetermined speed. This applies a coating of sealant to the peripheral surface of the applicator wheel.

Abstract: A roofing shingle is provided comprising a reduced-with headlap portion including headlap projections, a buttlap portion including buttlap projections, a lateral leading edge, and a lateral trailing edge, wherein the headlap projection nearest the lateral leading edge has an increased breadth. A roofing system is also provided comprising a multiplicity of courses of shingles of the invention, wherein a lateral trailing edge of a shingle in a single course overlaps (side-laps) an adjacent previously installed shingle, and wherein a shingle in a subsequent course provides a generally uniform overlap region over the headlap portions of a first and second adjacent shingle in the first course and an expanded overlap region over the second adjacent shingle, wherein the expanded overlap region is due to the increased breadth of the headlap projection nearest the lateral leading edge of the second adjacent shingle in the first course.