Abstract: An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. In one heavyweight underlayment, an oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer. In a lightweight underlayment, a split release sheet or facer segmented to provide a releasable selvedge edge and incorporating a high traction polymer on its surface is applied to the rubberized asphalt.

Abstract: A system (10) for recycling asphalt shingle scrap. There is a cold process, hot process, and a separation process. In the hot process, all of the components are ground except for the course surface granules. In the cold process, a type of grind is formed that is the same as the hot process except it is a dry powder. A horizontal mixer (20) can be used either hot or cold. The hot process and cold process can be run in combination with one another or independently. The component separation process uses a screen or the like (34) to separate the cold process material into surface granules, filled asphalt coating, and saturated felt component, while a magnet (38) may be used to help separate nails and other metal objects from the mixture.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material is broken up and separated and then provided to a recycling vessel. When the recycling vessel is operated in a cooled mode, dry ice may be added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of devices as well as at least one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be sorted by screening and stored as power or compressed into bricks or briquettes for later use in making various products.

Abstract: An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. In one heavyweight underlayment, an oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer. In a lightweight underlayment, a split release sheet or facer segmented to provide a releasable selvedge edge and incorporating a high traction polymer on its surface is applied to the rubberized asphalt.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used (post consumer) asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material, which may be in bundles, is broken up and separated and then provided to a cooled recycling vessel. Dry ice is added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of high speed shippers having tulip hear chipping teeth as well as one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be separated by screening and stored as power or compressed into bricks or briquettes.

Abstract: A system (10) for recycling asphalt shingle scrap. There is a cold process, hot process, and a separation process. In the hot process, all of the components are ground except for the course surface granules. In the cold process, a type of grind is formed that is the same as the hot process except it is a dry powder. A horizontal mixer (20) can be used either hot or cold. The hot process and cold process can be run in combination with one another or independently. The component separation process uses a screen or the like (34) to separate the cold process material into surface granules, filled asphalt coating, and saturated felt component, while a magnet (38) may be used to help separate nails and other metal objects from the mixture.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used asphalt materials. The asphalt material is broken up and separated. Dry ice may be added to the recycler and/or a jacket coolant used to cool the recycling vessel. The recycle vessel includes a number of high speed choppers having a blunt end as well as a horizontal mixer element with paddles. The recycled asphalt material is provided to a screener that may feature a plurality of sloping levels, each level including a tray below a screen and balls located within the tray that bounce due to vibration to prevent clogging of the screener. A second processing trip involving gravity feeding the material to be further recycled into a cutter with knife edges to further break down the size of the asphalt material is used for large particles that do not pass through the screener.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used (post consumer) asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material, which may be in bundles, is broken up and separated and then provided to a cooled recycling vessel. Dry ice is added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of high speed shippers having tulip hear chipping teeth as well as one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be separated by screening and stored as power or compressed into bricks or briquettes.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used (post consumer) asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material, which may be in bundles, is broken up and separated and then provided to a cooled recycling vessel. Dry ice is added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of high speed shippers having tulip hear chipping teeth as well as one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be separated by screening and stored as power or compressed into bricks or briquettes.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used asphalt materials. The asphalt material is broken up and separated. Dry ice may be added to the recycler and/or a jacket coolant used to cool the recycling vessel. The recycle vessel includes a number of high speed choppers having a blunt end as well as a horizontal mixer element with paddles. The recycled asphalt material is provided to a screener that may feature a plurality of sloping levels, each level including a tray below a screen and balls located within the tray that bounce due to vibration to prevent clogging of the screener. A second processing trip involving gravity feeding the material to be further recycled into a cutter with knife edges to further break down the size of the asphalt material is used for large particles that do not pass through the screener.

Abstract: An asphalt roofing material recycling system and method is used to recycle new and used (post consumer) asphalt materials, such as asphalt shingles, rolled roofing and tar paper that may include granules, fibers or other particles. The asphalt material, which may be in bundles, is broken up and separated and then provided to a cooled recycling vessel. Dry ice is added along with the asphalt material to be recycled. The dry ice removes any moisture present and super-cools the material making it brittle and easier to chip and break up. The recycle vessel includes a number of high speed shippers having tulip hear chipping teeth as well as one horizontal mixer element which stirs the material and makes sure all material is ground. The resulting course to fine powder can be separated by screening and stored as power or compressed into bricks or briquettes.

Abstract: An underlayment product comprises a fibrous mat having an upper surface and a lower surface. A rubberized asphalt coating is applied to the lower surface of the fibrous mat and extends at least partially into the fibrous mat. In one heavyweight underlayment, an oxidized asphalt coating is applied to the upper and lower surfaces of the fibrous mat generally encapsulating the fibrous mat including the rubberized asphalt coating provided on the lower surface of the fibrous mat. The oxidized asphalt layers may be coated with a release layer such as talc, granules or a polymer. In a lightweight underlayment, a split release sheet or facer segmented to provide a releasable selvedge edge and incorporating a high traction polymer on its surface is applied to the rubberized asphalt.

Abstract: A low-cost and easy to manufacture static structure and method for soundproofing walls, floors, and/or ceilings of rooms in new and/or existing construction utilizes an asphalt based flexible membrane as one or more sound absorbing layers which may be applied to an existing wall panel or first applied to one or more unmounted wall panels to form a laminated structure which is then affixed to the walls, floor or ceiling to be soundproofed. The wall panel is preferably gypsum wallboard. Each sound absorbing layer, in addition to soundproofing, may also serve to prevent or at least reduce air or water infiltration to and from the room.

Abstract: A self-adhesive product having a laser slit release liner and method provide improved performance and lower materials cost in self-adhesive products such as roofing and underlayment products, through-wall flashing, below-grade waterproofing and other rolled or flat roofing or other such self-adhesive weatherproofing products. A single piece release liner is applied to a roll or liner of material over a self-adhesive layer of the material. The release liner is cut into two or more segments using a laser beam. The laser beam oxidizes the adhesive region of the self-adhesive material in the area under the laser beam used to slit the release liner, thereby eliminating or minimizing unwanted adhesion caused by the migration of adhesive material when the product is rolled, stacked or stored. The laser beam may be used to create two or more segments in the release liner in a linear or curvilinear fashion.

Abstract: A low-cost and easy to manufacture static structure and method for soundproofing walls, floors, and/or ceilings of rooms in new and/or existing construction utilizes an asphalt based flexible membrane as one or more sound absorbing layers which may be applied to an existing wall panel or first applied to one or more unmounted wall panels to form a laminated structure which is then affixed to the walls, floor or ceiling to be soundproofed. The wall panel is preferably gypsum wallboard. Each sound absorbing layer, in addition to soundproofing, may also serve to prevent or at least reduce air or water infiltration to and from the room.

Abstract: The method of depositing granules in a frame pattern includes moving an asphalt-coated web and depositing successive granule blend drops on the web. The first blend drop has a first color and forms a first blend drop pattern defining an inner region. The second blend drop has a second color and forms a second blend drop pattern sized to fit within the inner region of the first blend drop such that the first blend drop frames the second blend drop. A third blend drop having a different third color or the same as the first color is deposited such that the third blend drop adheres to an intermediate region between the first and second blend drops. The system includes a mechanism for moving the web and an asphalt coater for coating the web with asphalt. First and second media applicators are used to deposit the first and second blend drops in the respective first and second blend drop patterns.

Abstract: A weatherproofing membrane having a high traction surface is used on a roof or other such location to prevent individuals from slipping. The weatherproofing membrane includes a facer sheet formed of a weatherproofing material and one or more polymer regions disposed on an upper side of the facer sheet. The weatherproofing membrane also includes a layer of modified asphalt disposed on the lower side of the facer sheet and a release backing disposed over the modified asphalt. The polymer is softer than the weatherproofing material and thus provides a higher traction surface than the weatherproofing material of the facer sheet. The polymer includes a low molecular weight polyethylene and an amorphous polyolefin (APO) in respective proportions ranging from about 50/50 to 90/10. The low molecular weight polyethylene and the APO are mixed hot and applied to the facer sheet, for example, using conventional coating techniques.

Abstract: An asphalt based material recycling system and method is used to recycle asphalt materials, such as asphalt shingles and tar paper that include granules, fibers or other particles. The asphalt material is simultaneously heated and milled in a heated milling apparatus, such as a heated ball mill, to reduce the asphalt material including granules to a fine mesh in suspension in liquid asphalt. Excess moisture is removed from the asphalt material being recycled by continuously venting the heated milling apparatus. The heated milling apparatus preferably includes a rotatable milling vessel rotated at an acute angle with respect to the horizontal plane and having an opening that provides continuous venting. The shape of the milling vessel allows the liquid level inside the milling vessel to have a liquid head above the outlet region of the milling vessel, for facilitating milling.

Abstract: A recycled asphalt roofing material for use on sloped roofs, which provides the required elevated melt point without using prior art methods of oxidizing the asphalt prior to incorporation into the roofing material is provided. The recycled asphalt roofing material is made up of approximately 30% flux asphalt and approximately 70% reclaimed asphalt roofing material. The fibrous backing in the reclaimed material modifies the asphalt in such a way as to provide the required elevated melt point. The manufacturing process for recycled fiberglass mat-based roll and shingle roofing, in its preferred embodiment, consists of impregnating a roofing material backbone, such as a fiberglass or polyester mat with recycled asphalt material to form inner and outer layers of recycled material and then applying optional second inner and outer layers of standard asphalt coating to the inner and outer layers of the recycled material.

Abstract: A recycled asphalt roofing material for use on sloped roofs, which provides the required elevated melt point without using prior art methods of oxidizing the asphalt prior to incorporation into the roofing material is provided. The recycled asphalt roofing material is made up of approximately 30% flux asphalt and approximately 70% reclaimed asphalt roofing material. The fibrous backing in the reclaimed material modifies the asphalt in such a way as to provide the required elevated melt point. The manufacturing process for recycled fiberglass mat-based roll and shingle roofing, in its preferred embodiment, consists of impregnating a roofing material backbone, such as a fiberglass or polyester mat with recycled asphalt material to form inner and outer layers of recycled material and then applying optional second inner and outer layers of standard asphalt coating to the inner and outer layers of the recycled material.