Abstract: Systems and methods of applying self-seal strips of multiple different adhesives are disclosed. In one embodiment, two spaced apart spoked applicator wheel assemblies are positioned beneath a web of moving shingle stock such that each of the applicator wheels applies dots of different adhesives in an alternating pattern. In other embodiments, a layer of a second adhesive is deposited onto previously applied dots of a first adhesive to form layered adhesive dots with dual properties of both adhesives.

Abstract: An applicator is disclosed for applying sealant to a moving substrate. The applicator includes a wheel having a periphery. A plurality of spaced apart footprints extends around the periphery of the wheel and each footprint has a sealant receiving feature. A reservoir is provided for containing a supply of sealant to be applied to the moving substrate. The wheel is rotatably mounted at least partially in the reservoir such that as the wheel rotates, each of the spaced apart footprints repeatedly moves through a supply of sealant in the reservoir to pick up a charge of sealant, around one side of the wheel toward the moving substrate, adjacent the moving substrate to transfer the sealant charge to the substrate, and around the other side of the wheel back toward the supply of sealant. At least one stop is formed on each of the footprints for inhibiting sealant picked up by the footprint from being urged rearwardly on the footprint by high speed rotation of the wheel.

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: Systems and methods of applying self-seal strips of multiple different adhesives are disclosed. In one embodiment, two spaced apart spoked applicator wheel assemblies are positioned beneath a web of moving shingle stock such that each of the applicator wheels applies dots of different adhesives in an alternating pattern. In other embodiments, a layer of a second adhesive is deposited onto previously applied dots of a first adhesive to form layered adhesive dots with dual properties of both adhesives.

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: A roofing shingle has an upper surface, a lower surface, and a sealant material applied along the lower surface. A pressure relief channel is formed along the lower surface of the roofing shingle, with a release strip applied over the pressure relief channel. When the roofing shingle is paired with another roofing shingle in a stack, the sealant material of the roofing shingle is arranged in registration with the release strip and pressure relief channel of the other roofing shingle.

Abstract: Roofing shingles are disclosed that are capable of being attached to a roof deck, underlayment, and/or other roofing shingles and that require fewer mechanical fasteners for attachment. The roofing shingles are formed with a first layer and a second layer of shingle materials that are laminated together, and with the first and second layers further being mechanically attached with indentations, including a first plurality of indentations formed along an upper surface of the first layer and a second plurality of indentations formed along a bottom surface of the second layer at spaced locations along the roofing shingles. A roofing system comprising a plurality of courses of the roofing shingles is also disclosed.

Abstract: Roofing shingles are disclosed that are capable of being attached to a roof deck, underlayment, and/or other roofing shingles and that require few mechanical fasteners to remain attached to the roof. The roofing shingles are formed with a first layer and a second layer of shingle materials that are laminated together, and with the first and second layers further being mechanically attached with indentations in the first and second layers at spaced locations along and across the roofing shingles. A roofing system comprising a plurality of courses of the roofing shingles is 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: A first plurality of roofing shingles installed in a first plurality of rows on a roof deck, and a second plurality of roofing shingles installed in a second plurality of rows. An edge of one of the second roofing shingles in each of the second rows is offset from the edge of another one of the second roofing shingles in another adjacent one of the second rows. An edge of a first photovoltaic shingle is juxtaposed with the edge of a first roofing shingle of the second roofing shingles in a first row of the second rows. The edge of at least another photovoltaic shingle in at least one of another row of the second rows is substantially aligned with the edge of the first photovoltaic shingle. An additional roofing shingle is installed intermediate one of the second roofing shingles and one of the photovoltaic shingles.

Abstract: A roofing shingle has an upper surface, a lower surface, and a sealant material applied along the lower surface. A pressure relief channel is formed along the lower surface of the roofing shingle, with a release strip applied over the pressure relief channel. When the roofing shingle is paired with another roofing shingle in a stack, the sealant material of the roofing shingle is arranged in registration with the release strip and pressure relief channel of the other roofing shingle.

Abstract: A first plurality of roofing shingles installed in on a roof deck, and a second plurality of roofing shingles installed in a second plurality of rows. An edge of one of the second roofing shingles in each of the second rows is offset from the edge of another one of the second roofing shingles in another adjacent one of the second rows. An edge of a first photovoltaic shingle is juxtaposed with the edge of a first roofing shingle of the second roofing shingles in a first row of the second rows. The edge of at least another photovoltaic shingle in at least one of another row of the second rows is substantially aligned with the edge of the first photovoltaic shingle. An additional roofing shingle is installed intermediate one of the second roofing shingles and one of the photovoltaic shingles.

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: A first plurality of roofing shingles installed in a first plurality of rows on a roof deck, and a second plurality of roofing shingles installed in a second plurality of rows. An edge of one of the second roofing shingles in each of the second rows is offset from the edge of another one of the second roofing shingles in another adjacent one of the second rows. An edge of a first photovoltaic shingle is juxtaposed with the edge of a first roofing shingle of the second roofing shingles in a first row of the second rows. The edge of at least another photovoltaic shingle in at least one of another row of the second rows is substantially aligned with the edge of the first photovoltaic shingle. An additional roofing shingle is installed intermediate one of the second roofing shingles and one of the photovoltaic shingles.

Abstract: A roofing shingle has an upper surface, a lower surface, and a sealant material applied along the lower surface. A pressure relief channel is formed along the lower surface of the roofing shingle, with a release strip applied over the pressure relief channel. When the roofing shingle is paired with another roofing shingle in a stack, the sealant material of the roofing shingle is arranged in registration with the release strip and pressure relief channel of the other roofing shingle.

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: A cap shingle configured to be installed over a hip or ridge of a roof structure, and a method for creating scored hinge lines in hip and ridge cap shingles during manufacturing while minimizing the likelihood of breakage along the scored hinge lines due to lane tension are disclosed. The method includes forming score lines with a scoring cylinder across lanes of shingle material just before the lanes are cut into individual cap shingles with a pattern cutter. The scoring cylinder and pattern cutter are controlled so that the score lines are consistently applied along the centerlines of the cap shingles.

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: Systems and methods of applying self-seal strips of multiple different adhesives are disclosed. In one embodiment, two spaced apart spoked applicator wheel assemblies are positioned beneath a web of moving shingle stock such that each of the applicator wheels applies dots of different adhesives in an alternating pattern. In other embodiments, a layer of a second adhesive is deposited onto previously applied dots of a first adhesive to form layered adhesive dots with dual properties of both adhesives.

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.