Abstract: An impact resistant roofing shingle comprising an upper shingle layer; a lower shingle layer laminated to said upper shingle layer underneath said tab portion of said upper shingle layer; wherein each of the upper shingle layer and the lower shingle layer comprise a mat, an upper asphalt coating layer applied to an exposed side of the mat, a lower asphalt coating layer applied to an unexposed side of the mat, a granular coating applied to the upper asphalt coating layer opposite the mat, and a fabric reinforcing layer applied to the lower asphalt coating layer opposite the mat. In one embodiment, the roofing shingle may also include the fabric reinforcing layer covering the entire area of each mat. The roofing shingle may have a recessed area of the exposed side of the overlay layer that aligns with the overlap of the overlay and underlay layers.

Abstract: Disclosed is an additive manufacturing process for making shingles and roof tiles. The entire shingle, including the substrate, can be manufactured on location, or a substrate can be manufactured at a manufacturing plant and then colored and textured on location to provide a wide variety of shapes and colors of shingles and roof tiles. Costs for inventory and shipping are reduced and a greater variety of shapes and colors can be provided for the shingles and roof tiles. The additive manufacturing equipment can be mounted on a truck so that the additive manufacturing techniques can be a mobile application of the additive manufacturing technology.

Abstract: A lightweight roofing shingle comprising a saturated mat having an exposed side and an unexposed side wherein a fabric reinforcing layer substantially replaces the bottom asphalt coating and the backing aggregate on the unexposed side of a conventional shingle. The lightweight shingle will have a top asphalt layer applied to the exposed side of the mat and a layer of granular material applied to the top asphalt layer opposite the mat per conventional construction, and the fabric reinforcing layer is adhered directly to the unexposed side of the saturated mat. In one embodiment, the fabric reinforcing layer covers an entire area of the unexposed side of the saturated mat. The reinforcing layer may preferably be a nonwoven fabric made from PET or polypropylene. The lightweight roofing shingle may also include a release tape layer applied to the reinforcing layer opposite the saturated mat.

Abstract: An asphalt coated roofing shingle including a mat substrate saturated with asphalt, a top asphalt layer on a top surface of the mat, a bottom asphalt layer on a bottom surface of the mat, a granular layer on the top asphalt layer and a layer of melt-blown fibers applied to the bottom asphalt layer. A method for making a lightweight roofing shingle including the steps of saturating a mat substrate wherein the mat substrate has a top surface and a bottom surface; applying a top asphalt layer to the top surface; applying a bottom asphalt layer to the bottom surface; applying a layer of granular material to the top asphalt layer opposite the mat after the top asphalt layer is applied to the top surface; and applying a layer of melt-blown fibers directly to the bottom asphalt layer after the bottom asphalt layer is applied to the mat substrate.

Abstract: An asphalt shingle coating system that includes a coater, a mixer, a viscosity gauge, a wax supply, a wax pump and a control system. The coater applies a layer of a coating asphalt mixture on an asphalt shingle substrate. The mixer mixes the coating asphalt mixture and is positioned upstream of the coater. The viscosity gauge may be positioned between the coater and the mixer, and it measures the viscosity of said coating asphalt mixture before it is delivered to the coater. The wax supply is in fluid communication with the mixer and a wax pump may deliver a volume of wax from the wax supply to the mixer, and the control system may selectively adjust the operation of the wax pump to substantially maintain a desired viscosity of said coating asphalt mixture.

Abstract: Disclosed is a release material that can be applied as a liquid, gel, emulsion, foam, etc. in a shingle manufacturing line. The release material can also be used in the manufacturing of roll roofing. The release material primarily constitutes an emulsion of polymers that can be cured with heat, IR light or other methods. Silicone may also be included in the emulsion which assists in releasability. The release material can be sprayed or extruded on to the surface of the shingle in an automated fashion, eliminating the necessity for operator interaction.

Abstract: Disclosed is impact resistant roofing that utilizes a heavy glass mat substrate having a weight of at least 3.0 lbs/csf that meets high impact resistance roofing standards. The impact resistant roofing utilizes a heavy glass mat that is embedded between two layers of asphalt. The impact resistant roofing can be manufactured on standard, existing roofing lines without modification.

Abstract: Disclosed is a multiple layer substrate that can be used with a top asphalt applicator that eliminates the need for a bottom asphalt applicator and fines applied to the bottom asphalt layer. A low porosity or impermeable bottom layer prevents the flow of asphalt applied to the porous top layers of the substrate from penetrating the bottom surface. This eliminates the need for fines to prevent sticking of shingles in a shingle stack. In addition, substrate layers that combine fiberglass and polyester fibers in various configurations provide a substrate that can be used in typical shingle manufacturing and manufacturing of waterproofing products that is impact resistant.

Abstract: An asphalt shingle manufacturing machine that includes a curtain die for applying a liquid release layer on an asphalt coated substrate. The moisture of the liquid release layer evaporates leaving a dispersed solid particulate release layer. The curtain die includes a first body section and a second body section with a shim disposed between the body sections to define a distribution channel. The second body section may include chamber manifold defined therein to store a volume of liquid release agent. The distribution channel places the chamber manifold in fluid communication with a discharge outlet of the curtain die in order to disperse a volume of liquid release agent from a chamber manifold out of the discharge outlet. The shim may be configured to define a width of the distribution channel to determine the flow rate and discharge pattern of the liquid release agent.

Abstract: Disclosed is waterproofing sheeting that uses a polyester layer that provides high lateral stability and puncture resistance. The waterproof sheeting can be used in many applications including waterproof roof underlayments waterproof sheeting for foundations, underlayment for tile and flooring and various other applications. The waterproof sheeting can be manufactured without many of the problems associated with the granular coatings of existing waterproof sheeting that create excessive wear and environmental hazards.

Abstract: An asphalt shingle having an asphalt-coated substrate sheet with a top surface and a bottom surface, wherein a liquid release layer is applied on the bottom surface of the asphalt shingle instead of conventional backing particulates. The liquid release layer may help the shingle proceed through the manufacturing machinery without sticking and may prevent the adhesion of the bottom surface of the asphalt shingle to an adjacent shingle in a stack of shingles upon experiencing a pressure up to around four pounds per square inch, a temperature of around eighty degrees Celsius or below. The liquid release agent may also prevent adhesion of adjacent shingles in a stack at various temperature and pressures for at least fourteen days.

Abstract: A roofing material comprising a substrate constructed at least in part of a carbon fiber material and a weather-resistant or water-proof coating affixed or applied to the substrate. Aesthetic or reflective materials may be applied to the exposed portion of said roofing material. The substrate may include woven and/or nonwoven fibers. The substrate may comprise a single layer or two or more layers of carbon-fiber material laminated by one or more binding layer. In addition, the present roofing material may include a bonding agent or primer for promoting adhesion between one or more carbon fiber substrate layers and/or a carbon fiber substrate layer and the weather-resistant or water-proof coating.

Abstract: Disclosed is impact resistant roofing that utilizes a heavy glass mat substrate having a weight of at least 3.0 lbs/csf that meets high impact resistance roofing standards. The impact resistant roofing utilizes a heavy glass mat that is embedded between two layers of asphalt. The impact resistant roofing can be manufactured on standard, existing roofing lines without modification.

Abstract: A lightweight roofing shingle comprising a saturated mat having an exposed side and an unexposed side wherein a fabric reinforcing layer substantially replaces the bottom asphalt coating and the backing aggregate on the unexposed side of a conventional shingle. The lightweight shingle will have a top asphalt layer applied to the exposed side of the mat and a layer of granular material applied to the top asphalt layer opposite the mat per conventional construction, and the fabric reinforcing layer is adhered directly to the unexposed side of the saturated mat. In one embodiment, the fabric reinforcing layer covers an entire area of the unexposed side of the saturated mat. The reinforcing layer may preferably be a nonwoven fabric made from PET or polypropylene. The lightweight roofing shingle may also include a release tape layer applied to the reinforcing layer opposite the saturated mat.

Abstract: Disclosed is a system for measuring and controlling the thickness of asphalt roofing materials during manufacturing. Light beams are used to generate a time of flight signal that is used to determine the thickness of the asphalt roofing layer. A controller generates a thickness control signal that controls a coater to modify parameters of the coater to produce the asphalt roofing layer with a desired thickness.

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: Disclosed is a release material that can be applied as a liquid, gel, emulsion, foam, etc. in a shingle manufacturing line. The release material can also be used in the manufacturing of roll roofing. The release material primarily constitutes an emulsion of polymers that can be cured with heat, IR light or other methods. Silicone may also be included in the emulsion which assists in releasability. The release material can be sprayed or extruded on to the surface of the shingle in an automated fashion, eliminating the necessity for operator interaction.

Abstract: Disclosed is a shingle that uses a polyester sheet as a substrate layer. The polyester sheet has a sufficient weight and is needled and formed from two layers to resist shrinking upon cooling after the heated asphalt layers are applied to the polyester substrate sheet 102. In addition, additives may be included in the asphalt to lower the softening point temperature of the asphalt that further reduces shrinking of the polyester substrate 102 or allows other polymers that are more fire retardant to be used. Fire retardants can be placed in the polyester sheet fibers, placed in the bonding agent for the polyester fibers, or the polyester sheet can be coated with the fire retardant. Alternatively, or in addition to treating the polyester sheet 102 with fire retardant, fire retardant materials such as ammonium sulfate can be added to the liquid asphalt prior to application of the asphalt layers.