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: 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 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 method of fabricating a polymer coated mat is disclosed to form a moisture barrier. The method includes moving a substrate mat along a processing path and heating the substrate mat to a predetermined temperature. A curtain of molten polymer is extruded through a slot die onto a surface of the heated substrate mat as the mat moves along the processing path to create a composite mat comprising a thin polymer film coating on at least one side of the substrate mat. The composite mat is then cooled in a controlled manner to cure and solidify the polymer film. The resulting composite mat may be used as a construction wrap, or it may be incorporated into other products such as an underlayment. A novel asphalt shingle may be fabricated using the composite mat in lieu of a traditional asphalt saturated mat or other substrate.

Abstract: The disclosed principles provide a roofing product and related methods of manufacturing having antimicrobial properties. The antimicrobial properties are provided by an antimicrobial delivery system including antimicrobial materials compounded, e.g., mixed together and melted, with polymeric materials. The antimicrobial delivery system is applied to roof covering material during the production process. The roof covering material may be sheets, shingles, panels, or roll stock.

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: 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: A roofing material comprising an upper surface and a lower surface, wherein the upper surface includes reduced-particle size granules and may further include a reduced-thickness face coating. The thickness of the upper surface is related to the particle size of the granules deposed on the face coating. A smaller particle size granule than those used in traditional roofing shingles is utilized in the upper surface which may allow for a reduced-thickness face coating while not sacrificing the retention of the granules on the surface of the roofing material or desired physical characteristics. The face coating may include a reduced amount of filler material, such as mineral fillers, than face coatings of traditional roofing materials.

Abstract: A finished flake for a roofing material including a metal flake substrate having an emissivity value up to approximately 0.25 and a reflectivity value up to approximately 0.95. A first coating is provided having unpigmented sodium silicate disposed on the substrate, wherein the first coating increases the emissivity value of the substrate and decreases the reflectivity value of the substrate. A second coating is provided having sodium silicate loaded with reflective pigments non-uniformly disposed about the first coating, wherein the finished flake has an emissivity value in excess of approximately 0.75 and a reflectivity value ranging from approximately 0.4 to approximately 0.5.

Abstract: The present disclosure relates, in some embodiments, to systems, articles, materials, and methods for roofing a structure including, for example, hybrid shingles comprising a first material and a second material. A hybrid shingle may comprise, in some embodiments, a first layer comprising a metallic substrate or a polymeric substrate and at least partially defining a headlap region of the shingle, a buttlap region of the shingle comprising one or more tabs interspersed with inter-tab openings, an outward-facing surface of the first layer, and a substrate-facing surface of the first layer; and a second layer comprising a base and asphalt, having a smaller area than the first layer, and at least partially defining a buttlap region of the shingle, wherein the second layer is fixed to the substrate-facing surface of the first layer.

Abstract: The present disclosure relates, according to some embodiments, to articles, systems, and methods for roofing a structure including, for example, layered shingles comprising a plurality of layers. A layered shingle may comprise, in some embodiments, an upper layer and a backing layer comprising a low density aggregate, wherein the backing layer is fixed to the substrate-facing surface of the upper layer.

Abstract: A single layer roofing material having a headlap portion and a tab portion wherein the headlap portion has a color-value gradient or gradation and the tab portion has tabs and openings. The tabs may have a relatively uniform color. Openings between tabs expose the color gradient of the headlap portion when a first sheet of the roofing material is installed over a second sheet on a structure. A plurality of horizontal striations may be used to establish the desired color-value gradient. An illusion of depth or thickness is created when the roofing material is applied to a structure, such as a roof deck. The amount of tone and contrast may be selected to create the desired illusion of depth or thickness. The amount of contrast may be varied depending upon the color selected for each roofing material. The number of horizontal striations and their width may also be varied to provide the desired color-value gradient. Tab color, shape and size may also be varied to enhance the illusion of depth.

Abstract: A solar roofing panel has a rectangular body with solar cells exposed on the upper surface of the body and an electrical junction box on the lower surface of body along the forward edge portion thereof. A cutout is formed in the upper edge portion of the rectangular body at a corner thereof. When a plurality of solar panels are arranged on a roof in courses with an upper course partially overlapping a lower course, the junction boxes of roofing panels in the upper course are disposed in the cutouts of roofing panels of the lower course. Accordingly, the solar roofing panels present a low profile mimicking the profile of slate-style shingles.

Abstract: A solar roof shingle for providing AC electrical power when exposed to sunlight includes a shingle frame having a bottom panel supportable on a roof deck, a top panel, and a thickness between the bottom panel and the top panel. The solar roof shingle also includes a solar collector mounted to and covering at least a portion to the top panel of the shingle frame, with the solar panel producing DC electrical energy at DC terminals when the solar collector is exposed to sunlight. A nano-inverter is disposed within the shingle frame between the bottom panel and the top panel and is electrically coupled to the DC terminals. The nano-inverter converts DC electrical energy to AC electrical energy available at AC terminals mounted to the shingle frame.

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 finished flake for a roofing material including a metal flake substrate having an emissivity value up to approximately 0.25 and a reflectivity value up to approximately 0.95. A first coating is provided having unpigmented sodium silicate disposed on the substrate, wherein the first coating increases the emissivity value of the substrate and decreases the reflectivity value of the substrate. A second coating is provided having sodium silicate loaded with reflective pigments non-uniformly disposed about the first coating, wherein the finished flake has an emissivity value in excess of approximately 0.75 and a reflectivity value ranging from approximately 0.4 to approximately 0.5.

Abstract: The present disclosure relates, according to some embodiments, to single ply roofing membranes comprising a top layer, a scrim layer, and a bottom layer. A bottom layer may comprise a bottom layer surface having at least one non-embossed band and an embossing region comprising embossing. Embossing may extend from the bottom layer surface into the bottom layer and may comprise truncated pyramids or frustums with curvilinear bases.

Abstract: A roofing system comprising laminated roofing shingles having a reduced-width headlap portion and a buttlap portion, wherein the roofing system comprises a plurality of courses, and wherein a trailing edge of a subsequently installed shingle in a course overlaps the leading edge of an adjacent previously installed shingle in the same course. The reduced-width headlap portion of the roofing shingles has a width that is less than the width of the buttlap portion. The roofing shingle comprises a first and a second shingle sheet and the lateral edges of the first shingle sheet are aligned with the lateral edges of the second sheet.

Abstract: A solar ridge vent includes an elongated laterally flexible panel having edge portions and ventilation grids extending along the edge portions. Channel members extend along the edge portions of the panel and define channels that have channel openings facing inwardly. The channels are sized to receive edges of auxiliary components to hold the auxiliary components on the ridge vent. The auxiliary components may be ridge cap shingles, slate cap shingles, light emitting emergency location panels, or fluid heating panels. In a preferred embodiment, solar power generating panels are configured to be mounted on the ridge vent with its edges held in the channels. A remote electrical box has chargeable batteries, a power inverter, and an AC outlet to provide electrical power in an emergency.

Abstract: A solar roof shingle for providing AC electrical power when exposed to sunlight includes a shingle frame having a bottom panel supportable on a roof deck, a top panel, and a thickness between the bottom panel and the top panel. The solar roof shingle also includes a solar collector mounted to and covering at least a portion to the top panel of the shingle frame, with the solar panel producing DC electrical energy at DC terminals when the solar collector is exposed to sunlight. A nano-inverter is disposed within the shingle frame between the bottom panel and the top panel and is electrically coupled to the DC terminals. The nano-inverter converts DC electrical energy to AC electrical energy available at AC terminals mounted to the shingle frame. The nano-inverter has a maximum power rating of 150 Watts or less so that it produces substantially less heat during operation allowing the thickness of the solar roof shingle to approach that of a standard roofing shingle.