Abstract: A siding panel assembly includes an ornamental facing and a first insulation layer made from fibrous insulating material. That fibrous insulating material includes polymer fibers and glass fibers, polymer fibers, natural fibers and mixtures thereof. A method for making the siding panel assembly includes the steps of cutting a groove in and molding a first surface of a sheet of the insulation layer to match in profile a concavity in the ornamental facing and assembling the insulation layer and the ornamental facing.

Abstract: A prefabricated wall panel has a precast body including at least one decorative design element. In addition, the wall panel includes a mounting element having a first end embedded in the precast body and a second end projecting from the precast body. A groove is formed between the precast body and the second end of the mounting element along a first edge of the precast body. A tongue is formed along a second edge of the precast body opposite the first edge. The tongue and groove cooperate to allow prefabricated wall panels to be more easily installed on a support substrate.

Abstract: A process of producing a roofing shingle coating asphalt from an asphalt feedstock includes the following steps. Wax and blowing catalyst are added to the asphalt feedstock. Then the asphalt feedstock is blown to produce the coating asphalt. The coating asphalt has a softening point within a range of from about 190° F. (88° C.) to about 235° F. (113° C.) and has a penetration of at least about 15 dmm at 77° F. (25° C.).

Abstract: In a process of producing a roofing shingle coating asphalt from a low flashpoint asphalt feedstock, an asphalt feedstock which has a low flashpoint of from 490° F. (254° C.) to 540° F. (282° C.) is partially blown, and wax is added to the asphalt feedstock. The process produces a coating asphalt having a low melt viscosity of from 50 cps to 150 cps at 400° F. (204° C.), a softening point of from 190° F. (88° C.) to 235° F. (113° C.) and a penetration of at least 15 dmm at 77° F. (25° C.). In another embodiment, the process produces a roofing shingle coating asphalt having good weatherability from a poor weathering asphalt feedstock. In a further embodiment, the process produces roofing shingles including a filled coating containing a poor tear filler without sacrificing the tear strength of the shingles.

Abstract: A compound includes a combination of materials for manufacturing a resin based product. The materials include a blend of asphalt and resin. The asphalt functions as at least one of a colorant to change the color of the product and a resin replacement to reduce the amount of resin in the product. The asphalt is included in an amount within a range of from 0.1% to 40% by weight of the compound. A pellet for use in the compound includes from 40% to 90% asphalt and from 10% to 60% resin by weight of the pellet. The asphalt has a softening point from 200° F. to 350° F.

Abstract: A board suitable for installation on the side of a building has a front surface suitable for exposure to the weather, a rear surface, an upper end and a lower end, wherein the board has a stacking foot at either the upper end or lower end of the board, and has a stacking notch at the other of the upper end or lower end, with the stacking notch and the stacking foot enabling two of the boards to be stacked together with the stacking foot of each of the boards nested in the stacking notch of the other board, thereby providing stability for the stacked boards.

Abstract: A consumable container is molded from a composition comprising 40 to 90 weight % of an asphalt and 10 to 60 weight % of a polymer material, which advantageously can include a first polymer such as PP that imparts heat resistance and a second polymer such as EVA that imparts toughness and impact resistance. This molded asphalt/polymer material preferably has an unnotched Izod impact strength of at least 2 joules. The container is consumable--it can be melted along with roofing asphalt held in the container without adversely affecting the properties of the asphalt and without requiring undue mixing. The composition also can be used to reduce fumes normally emitted from a kettle of molten asphalt, e.g., as measured by a reduction of the visual opacity of the fumes by at least 25%, a reduction of the hydrocarbon emissions of the fumes by at least 20%, or a reduction of the total suspended particulates emissions of the fumes by at least 15%. The container may be used, e.g.

Abstract: A method and apparatus for packaging a low-fuming meltable asphalt composition which includes the introduction of pellets comprising one or more polymeric materials into molten asphalt flowed into a conventional container or carton.

Abstract: A penetration pocket, useful to seal roof openings at protruding pipes or the like, is made of a material compatible with roofing asphalt. The penetration pocket material is asphalt-based with polymeric materials added to impart strength and toughness. Fibrous material may also be added for increased strength. The roofing asphalt, when applied around the penetration pocket, fuses with penetration pocket walls and base, and upon cooling, the penetration pocket and the roofing asphalt are welded together to effect a secure, water-proof joint.

Abstract: Asphalt is packaged in consumable containers (10) having breakage means, such as short notches or long channels (110, 111), to allow for easy breakage into smaller portions for ease of handling and feeding into kettles. The containers are advantageously made of an asphalt-polymer composition so that the entire asphalt package may be melted in a kettle, e.g., for use in a roofing or paving application. The containers may have various features to enhance processability and handleability, including a generally rectangular shape and multi-faceted or stepped sides 20 and/or walls 30 with handhold portions and/or scooped portions.

Abstract: A consumable container is molded from a composition comprising 40 to 90 weight % of an asphalt and 10 to 60 weight % of a polymer material, which advantageously can include a first polymer such as PP that imparts heat resistance and a second polymer such as EVA that imparts toughness and impact resistance. This molded asphalt/polymer material preferably has an unnotched Izod impact strength of at least 2 joules. The container is consumable--it can be melted along with roofing asphalt held in the container without adversely affecting the properties of the asphalt and without requiring undue mixing. The composition also can be used to reduce fumes normally emitted from a kettle of molten asphalt, e.g., as measured by a reduction of the visual opacity of the fumes by at least 25%, a reduction of the hydrocarbon emissions of the fumes by at least 20%, or a reduction of the total suspended particulates emissions of the fumes by at least 15%. The container may be used, e.g.

Abstract: An injection molding process and apparatus to manufacture asphalt-based products which utilizes a heated mixing chamber to continuously blend molten thermoplastic polymer and asphalt to form an injection moldable composition.

Abstract: A penetration pocket, useful to seal roof openings at protruding pipes or the like, is made of a material compatible with roofing asphalt. The penetration pocket material is asphalt-based with polymeric materials added to impart strength and toughness. Fibrous material may also be added for increased strength. The roofing asphalt, when applied around the penetration pocket, fuses with penetration pocket walls and base, and upon cooling, the penetration pocket and the roofing asphalt are welded together to effect a secure, water-proof joint.

Abstract: Asphalt/polymer fibers include, by weight, 30% to 85% polymeric material and 15% to 70% asphaltic material, where the polymeric material has a melt flow index of no more than about 35 grams/10 minutes. Preferably, the combination of polymeric material and asphaltic material has a melt flow index of from 80 grams/10 minutes to 800 grams/10 minutes. The asphaltic material is preferably asphalt having a softening point of from 82.degree. C. to 177.degree. C. The polymeric material is preferably a polymer selected from polypropylene, polyethylene, polystyrene, polyesters, ethylene copolymers, acrylates, methacrylates, and mixtures of these polymers. The organic fibers of asphalt/polymer may be intermingled with mineral reinforcing fibers and formed into products such as mats.

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: Asphalt is packaged in consumable containers (10) having breakage means, such as short notches or long channels (110, 111), to allow for easy breakage into smaller portions for ease of handling and feeding into kettles. The containers are advantageously made of an asphalt-polymer composition so that the entire asphalt package may be melted in a kettle, e.g., for use in a roofing or paving application. The containers may have various features to enhance processability and handleability, including a generally rectangular shape and multi-faceted or stepped sides 20 and/or walls 30 with handhold portions and/or scooped portions.

Abstract: A glass fiber mat contains between 68% and 90% glass fibers and between 10% and 32% binder by weight of the mat. The binder contains between 2% and 90% polymer modified asphalt and between 10% and 98% thermosetting resin by weight of the binder. The polymer which modifies the asphalt is selected from thermoplastic and/or thermoset polymers. A preferred thermoplastic polymer is selected from reactive thermoplastic polymers and/or thermoplastic elastomers. The binder is preferably applied to the glass fibers in the form of a blend of thermosetting resin and an aqueous emulsion of polymer modified asphalt. The aqueous emulsion is prepared by combining between 5% and 75% asphalt, between 2% and 20% polymer selected from thermoplastic and/or thermoset polymers, between 25% and 95% water, and between 0.5% and 5% surfactant by weight of the aqueous emulsion.

Abstract: A consumable container is molded from a composition comprising 40 to 90 weight % of an asphalt and 10 to 60 weight % of a polymer material, which advantageously can include a first polymer such as PP that imparts heat resistance and a second polymer such as EVA that imparts toughness and impact resistance. This molded asphalt/polymer material preferably has an unnotched Izod impact strength of at least 2 joules. The container is consumable--it can be melted along with roofing asphalt held in the container without adversely affecting the properties of the asphalt and without requiring undue mixing. The composition also can be used to reduce fumes normally emitted from a kettle of molten asphalt, e.g., as measured by a reduction of the visual opacity of the fumes by at least 25%, a reduction of the hydrocarbon emissions of the fumes by at least 20%, or a reduction of the total suspended particulates emissions of the fumes by at least 15%. The container may be used, e.g.

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: Asphalt/polymer fibers include, by weight, 30% to 85% polymeric material and 15% to 70% asphaltic material, where the polymeric material has a melt flow index of no more than about 35 grams/10 minutes. Preferably, the combination of polymeric material and asphaltic material has a melt flow index of from 80 grams/10 minutes to 800 grams/10 minutes. The asphaltic material is preferably asphalt having a softening point of from 82.degree. C. to 177.degree. C. The polymeric material is preferably a polymer selected from polypropylene, polyethylene, polystyrene, polyesters, ethylene copolymers, acrylates, methacrylates, and mixtures of these polymers. The organic fibers of asphalt/polymer may be intermingled with mineral reinforcing fibers and formed into products such as mats.