U.S. patent number 3,886,021 [Application Number 05/337,636] was granted by the patent office on 1975-05-27 for process for making non-felt, laminar roofing material such as composition shingles and the like.
This patent grant is currently assigned to U.I.P. Engineered Products Corporation. Invention is credited to Ernst G. Breckenfelder.
United States Patent |
3,886,021 |
Breckenfelder |
May 27, 1975 |
Process for making non-felt, laminar roofing material such as
composition shingles and the like
Abstract
A method of producing an asphalt roofing composition as well as
a novel roofing composition product is disclosed wherein the usual
felt base is eliminated. Layers of flowable, viscous asphalt are
applied over a moving belt surface and a fiber glass material is
introduced between the two layers. In a preferred form, a release
agent is placed between the first layer of asphalt applied onto the
moving belt surface so as to afford easy removal of the laminated
asphalt composition from the belt. The feltless, laminated roofing
composition has the advantage of eliminating the use of the usual
saturators associated with felt backing type shingles and at the
same time affording the reuse of any scrap material.
Inventors: |
Breckenfelder; Ernst G.
(Elmhurst, IL) |
Assignee: |
U.I.P. Engineered Products
Corporation (Elk Grove Village, IL)
|
Family
ID: |
23321358 |
Appl.
No.: |
05/337,636 |
Filed: |
March 2, 1973 |
Current U.S.
Class: |
264/300; 156/279;
264/308; 427/203; 156/246; 156/289; 427/186 |
Current CPC
Class: |
B29C
41/32 (20130101); E04D 1/28 (20130101); E04D
2001/005 (20130101) |
Current International
Class: |
E04D
1/28 (20060101); E04d 005/08 (); B32b 011/02 () |
Field of
Search: |
;161/236,162,158,93,DIG.4 ;156/246,247,289,279,299,71
;117/32,30 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Ansher; Harold
Attorney, Agent or Firm: Barry; Ronald E.
Claims
I claim:
1. A method of producing an asphalt roofing composition comprising
the steps of applying a first layer of viscous flowable asphalt
onto a continuously moving supporting surface to effect a first
layer of plastic asphalt material, blowing a fibrous material onto
said first layer of asphalt material while said first layer is in a
plastic state, applying over said fibrous coated asphalt material
while in a plastic condition a second layer of viscous flowable
asphalt to effect a second layer of plastic asphalt material to
result in a laminated roofing composition material, positively
cooling said laminated composition and removing said composition
from said continuously moving supporting surface.
2. A method as defined in claim 1 wherein said supporting surface
is a moving belt.
3. The method as defined in claim 1 wherein said fibrous material
are strands of chopped fiber glass.
4. The method as defined in claim 1 wherein said flowable viscous,
asphalt material is bituminous asphalt containing a compatible
filler material.
5. The method as defined in claim 2 including the step of applying
a release agent to said moving belt prior to the application of
said first layer of viscous flowable asphalt.
6. The method as defined in claim 5 including the step of placing
strips of backing material on said release agent prior to the
application of said first layer of viscous, flowable asphalt.
7. The method as defined in claim 1 wherein said first and second
layers of asphalt material are applied in equal amounts.
8. The method as defined in claim 1 including the step of
maintaining the temperature of the viscous, flowable asphalt
material in the range of 250.degree.-350.degree.F.
9. The method as defined in claim 1 including the step of mixing
limestone dust in the flowable, viscous asphalt prior to applying
the asphalt to the supporting surface.
10. The method as defined in claim 5 wherein said release agent is
limestone dust.
Description
BACKGROUND OF THE INVENTION
This invention relates to the production of roofing materials. More
particularly, it relates to a process and roofing composition which
is produced without the use of a felt or belt type backing and
eliminating the usual problems associated with the felt type
shingle production such as the use of saturators which can cause
pollution problems and the handling of the felt based backing which
can, because of its weakness, break and cause delays.
The most commonly used method in making composition asphalt roofing
is to use dry felt paper as a web and carrier to receive the
asphalt, filler material and granules. The process requires that
this felt be unwound and immersed or sprayed with molten asphalt at
425.degree.-475.degree.F for complete saturation of the felt fibers
and to fill the tiny voids in the felt sheet. The surfaces of the
saturated felt are then coated with a filled asphalt material such
as limestone dust and an asphalt mixture to build up the thickness
and weight to various specifications, the most common being 235
lbs./roofing square. Prior to the cooling of this asphalt coating,
the granules are dropped and embedded or impressed into the soft
molten surface. From this point the sheet is cooled and processed
into rolls or shingles of various sizes the most common being known
as 12 .times. 36 square tabs. Such procedures are generally
indicated in U.S. Pats. No. 2,112,819 and 2,893,889.
The disadvantage of this system of manufacture is the use of dry
felt paper which is inherently weak and requires periodic splicing
of rolls. The only purpose of the felt is to convey the molten
asphalt material through the various processes. Because of its
weakness and low tensile strength, it repeatedly breaks causing
costly delays in manufacture. This felt requires the initial
saturation to make it impervious to moisture and subsequent
deterioration. The presently used saturators are large multi-roll
machines with large deep tanks for immersing the dry felt into the
molten asphalt. Due to the large quantities of asphalt and the
circulation there is a great heat lost. Also, asphalt when heated
gives off obnoxious fumes when open to the atmosphere. Hooding and
fume removing equipment are necessary to get rid of these fumes.
Further, the molten asphalt is also a fire and safety hazard.
In U.S. Pat. No. 2,619,675, a manufacturing procedure which does
not utilize a felt base is described. However, this process
requires the use of an extruder which requires high extruder forces
in order to force the asphalt material from the nozzle and precise
controls to assure that the extruded sheet is of uniform dimension
and is self-supporting.
In the present proposed method and resulting shingle article, the
saturator and all attendant equipment is eliminated as dry felt
paper would not be used, eliminating splices and breaks. There
would be virtually no fumes because the large open volumes of
asphalt at high temperatures would be eliminated. Fire hazards now
present in a saturator would be foreclosed and the resulting end
product would carry a better fire rating as it would not contain
dry felt paper. In addition, the present process does not require
high extruding forces or precise controls for forming an extruded
self-supporting sheet material.
It is an object of the present invention to provide a novel process
and roofing composition wherein the usual felt base is no longer
employed. It is another object of this invention to provide a
process and roofing article wherein the usual saturator employed to
make felt type roofing compositions is eliminated. It is still
another object of this invention to provide a method and article
wherein any scrap material which may result can be easily recycled.
It is yet another object of this invention to provide a process for
making asphalt roofing composition materials which will afford the
application of molten asphalt over a moving belt surface and a
material utilized for its removal from the moving belt to be
further utilized in orientating cut roofing shingles into stacks
for packaging and later use.
SUMMARY OF THE INVENTION
The foregoing objects are accomplished and the shortcomings of the
prior art are overcome by the present process and product produced
therefrom wherein a first layer of viscous, flowable asphalt is
applied onto a supporting surface to effect a first layer of
plastic asphalt material with the immediate application of a
fiberous material onto the first layer while the first layer is in
a plastic self-supporting state. While in this plastic state a
second layer of asphalt material is flowed over the fibrous coated
first layer to result in a laminated roofing composition material.
The usual slate granules are applied over the second layer in the
normal manner and the resulting product is cooled and removed from
the supporting surface. In a preferred manner, the first stripe or
layer of asphalt material is applied in a flowable manner using
pumping pressures which will allow the liquid asphalt to flow onto
a moving belt. A release agent is applied prior to the application
of the first layer onto the moving belt and the subsequent layer
and fibrous material is applied to this first layer. A filler
material is utilized in the flowable asphalt for both layers and it
can be the same material as utilized for the release agent. Backing
strips are also readily adaptable to the process and can be applied
over the release agent prior to the application of the first layer.
The temperature of the viscous, flowable asphalt is preferably in
the range of 250.degree.-350.degree.F and is applied onto the
moving belt as a flowable liquid. After it is applied over the
belt, it sets up into a plastic mass having adhesive qualities and
permitting the embedding of fiber glass and adherence of the
subsequent liquid layer of asphalt. A unique asphalt roofing
composition results from this process in that it does not have a
felt base yet it is a homogenous web with the filled asphalt
serving as the binder and the fibrous material giving it tensile
strength.
BRIEF DESCRIPTION OF DRAWINGS
A better understanding of the present process and the article
produced thereby will be afforded by reference to the drawings
wherein:
FIG. 1 is a perspective view illustrating a portion of the
apparatus for carrying out the unique method of this invention.
FIG. 1a is a view similar to FIG. 1 except showing a continuation
of the apparatus described in FIG. 1.
FIG. 2 is a view in vertical section taken along line 2--2 of FIG.
1.
FIG. 3 is a view in vertical section taken along line 3--3 of FIG.
1a.
DESCRIPTION OF THE METHOD EMBODIMENT.
The method of this invention comprises the steps of applying a
first layer of viscous, flowable liquid-like asphalt onto a
supporting surface to effect a first layer of plastic asphalt
material which is self-supporting yet will allow a fibrous material
such as fiber glass to be forced onto it. A fibrous material, such
as fiber glass is then blown with force into the first layer and
while the first layer is in a plastic state a second layer of
liquid, flowable, viscous asphalt material is applied over the
first layer with the fibers. While the second layer is in the
plastic state slate granules are applied over it and the resulting
laminated composition is then cooled and removed from the
supporting surface. In a preferred manner, the first layer of
liquid, flowable, viscous asphalt is placed in the form of a stripe
onto a moving belt surface to which is previously applied a release
agent such as limestone dust. The fibrous material which is applied
between the two layers is preferably fiber glass and is suitably
blown onto the first plastic layer of asphalt by means of fiber
glass chopper applicators which are of the gun type. The preferred
temperature of the viscous liquid, flowable asphalt is in the range
of 250.degree.-350.degree.F and in a like manner the second layer
as it is applied is in the same temperature range. The release
agent is placed on a moving belt in excess of 100% in the area
where the product is to be applied. The first coat would preferably
be of 1/16 inch and the fiber glass interjected into it at the rate
of 11/4 ounces per 9 square feet. The fiber strands should be
controlled to be of a length of approximately 1 inch to 11/2 inches
and be about 1 mil. thick. The second layer of asphalt material
would be of the same width as the first and would be applied to the
first layer when it is in a molten plastic and somewhat
self-supporting state. The fibrous materials would not lend any
thickness to the material but by being fed through a chopper the
ends become split giving binding strength. The width of the moving
compositioned layers can be of any dimension desired by merely
regulating the orifice of the applicator through which the heated
asphalt material is caused to flow. The usual granules are then
applied over the second layer while it is in a plastic state and
the entire resulting product is later cooled, cut and stacked for
shipping. The resulting product is in effect a laminar or
sandwiched type composition in that two layers of asphalt material
will in effect be formed with fiber glass there between and slate
granules on the top and with no felt base being employed.
DESCRIPTION OF APPARATUS AND OPERATION FOR EFFECTING METHOD
A better understanding of the method of this invention and the
production of the article of this invention will be had by a
description of the apparatus described in FIGS. 1 and 1a, generally
indicated by the numeral 10, and its operation. A continuous
conveyor belt 11 is rotatably supported over and driven by rollers
12 and 13. Belt 11 is composed of fibrous material such as woven
cotten. Disposed above belt 11 and adjacent roller 12 is a hopper
14 containing a release agent 15, such as limestone dust, which is
fed in a continuous and uniform manner from hopper 14 by means of
roller applicator 17 down onto belt 11. Three spools 18a, 18b and
18c have wound thereon silicone treated backing strips 19a, 19b and
19c, respectively, which spools are rotatably mounted over belt 11
and apply backing strips 19a, 19b and 19c, onto the release coated
belt 11. A liquid asphalt applicator 20 is disposed across belt 11
with an orifice 21 for applying the first ribbon or stripe of
liquid asphalt material which will become plastic and somewhat
self-sustaining when it contacts the release agent 15 on belt 11.
This is indicated by the numeral 23. Applicator 20 is supplied with
filled asphalt material by means of several devices which will now
be described.
A filler hopper 25 will contain the filler material such as
limestone dust and will flow downwardly through the hopper and be
moved laterally from it by means of auger 26 rotatably disposed in
tubular conduit 27, with auger 26 being rotated by means of motor
28 which drives sheave 29 secured to auger 26. Sheave 29 is driven
by belt 30 which in turn engages motor sheave 31. The filler
material will then enter into a continuous mixer 32 by means of
intermediate conduit 33. Continuous mixer 33 contains a paddle
agitator 34 which will be driven by means of motor 35, motor sheave
36, belt 37 and paddle agitator sheave 38. Continuous mixer 32 is
of the heated jacketed variety and heated asphalt at temperature of
350.degree.-400.degree.F is introduced through inlet 39 in pump 40
which is driven by sheaves 41 and 42, interconnected by belt 43 to
motor 44. After suitable mixing with the hot asphalt and the filler
material, the combined product will flow downwardly through conduit
45 from chamber 32 into pump 46 which is driven by sheaves 47 and
48, interconnected by belt 49 driven by motor 50, with sheave 48
driving transmission 51 for filled coating pump 46. The filled
asphalt product will flow down conduit 52 into asphalt applicator
20 and ultimately out orifice 21 to subsequently form first layer
of asphalt 23.
Two fiber glass chopping guns 53a and 53b will blow chopped fiber
glass 54 onto first layer 23 and will become embedded therein. Both
chopping guns 53a and 53b being supplied by the usual fiber glass
inlet conduits 55a and 55b and air intakes 56a and 56b. After the
chopped fiber glass is blown into the first layer 23 of asphalt
material the resulting product will pass beneath a second liquid
asphalt applicator 120 which is positioned the same as applicator
20 but spaced therefrom. Applicator 120 is supplied by the same
means which function in the same manner and, consequently, all of
the components as well as applicator 120 itself are numbered in the
"100" series and each will not be repeated. Applicator 120 will
flow liquid asphalt out from orifice 121 under the same temperature
conditions as that indicated for applicator 20 and orifice 20 to
result in a second asphalt layer 58 of a self-supporting plastic
consistency which will be moved by means of belt 11 under slate
granule blender applicators 60 containing compartments such as 61
for the various types of color granules. These are of the standard
variety and will be applied onto the second layer 58 by means of
roller applicators 62. After having the granules 66 applied to the
second layer 58 belt 11 will move the slate covered two layered
composition beneath cooling fan 63 driven in the usual manner by
sheave 64 to force air down into cooling chamber 57 and out through
the three chambered orifices 65. Positioned immediately downstream
from cooling fan 63 are a pair of press rolls 67 and 68 which are
rotatably supported on opposite sides of belt 11 with press roll 67
being water cooled for pressing granules 66 into layer 58. Also
disposed above belt 11 are pairs of standard water sprayers 70 and
71 which will apply cooling water to the pressed laminar asphalt
composition 73 by means of nozzles 74 and 75, respectively, with
water sprayers 70 and 71 being in communication with water inlet
pipe 78. Valves 79 and 80 control the flow of water to water
sprayers 71 and 70 which will be under suitable pressure. Two air
blowers 81 and 82 with knife-like orifices 83 and 84 will apply air
at high pressures to drive the water from the asphalt composition
73 after each application of water from water sprayers 70 and 71
with the air being suitably forced into the knife-like applicators
83 and 84 by means of blower mechanisms 85 and 86.
A release agent collector hopper 87 is suitably disposed adjacent
roller 13 to collect excess release agent 15 and in a similar
manner granule collector hopper 88 is positioned adjacent roller
89, with roller 89 and roller 90 being powered to lift laminar
asphalt composition 73 upwardly across the support roller 91 and
through a seal down applicator 92. Three rows of adhesive-like
asphalt such as indicated at 93 are applied by applicator 92 by
means of tray 94 and a dipping applicator wheel such as shown at 95
which is of the cog type to apply the seal down material 93 in a
spaced manner. Roller 96 affords the necessary force during
application of the adhesive asphalt. After passing from support
roller 97 the asphalt laminar product 83 can be cut into various
sizes of shingles by punching and wrapping in the usual manner. It
will be noted that backing strips 19a, 19b and 19c will be
orientated opposite to the three rows of adhesive 93 so as to
prevent sticking to the adjacent shingles when they are
packaged.
The form of the laminar shingles as they are produced
intermediately is shown in FIG. 2 and ultimately in FIG. 3. It will
be noted in FIG. 3 that a laminar product 73 is produced with the
two layers of asphalt 23 and 58 with fiber glass 54 therebetween
and granules 66 at the top with no felt material being
employed.
In the previous description of the invention, limestone dust is
indicated for the release agent 15 as well as the filler material
in filler hopper 25 for mixing with the asphalt which is applied by
means of applicators 20 and 120. It should be understood that other
materials for the release agent 15 could be employed such as
portland cement, talc or mica. Similarly, fly-ash and sand could be
utilized in hopper 25 as the filler material. A belt 11 has been
referred to for use in fabricating the laminar asphalt composition
73. It should be understood that any conveyor belt which would have
a surface which is smooth and resistant to adhesion to asphalt such
as stainless steel, Teflon, Delrin and the like which could
withstand the temperatures required could be utilized. Chopping
guns 53a and 53b are utilized for applying the fiber glass onto the
molten asphalt layer 23. These are of the standard Binks type. Any
chopper type guns which will blow glass fibers onto the molten
asphalt material can be substituted.
It will thus be seen that through the present invention there is
now afforded a method for producing asphalt composition shingles
which completely eliminates the felt type base and its inherent
saturators. The method is readily adaptable to a continuous type
process and utilizes asphalt material at a reduced temperature so
that fumes surrounding production are kept to a minimum while
capital investment for equipment is also kept low. The process
lends itself readily to automation and any material which should
result as scrap can be readily recycled into usuable material which
in the instance of asphalt felt base material cannot be done. In
the instance where a release agent is employed to readily remove
the laminar product from the belt this release agent also serves
the purpose of allowing the subsequently cut shingled material to
be slide over each other in stacking as well as later use during
application. The laminar product produced by this invention has
suitable tensile strength so as to be comparable in every way to
that of the felt base type shingle.
The foregoing invention can now be practised by those skilled in
the art. Such skilled persons will know that the invention is not
necessarily restricted by the particular embodiments herein. The
scope of the invention is to be defined by the terms of the
following claims as given meaning by the preceding description.
* * * * *