Note: Descriptions are shown in the official language in which they were submitted.
A METHOD OF MAKING AN ASPHALT SHINGLE WITH SYNCHRONIZED
ADHESIVE POSITIONING THEREON
Background of the Invention
Asphalt shingles have been manufactured for many years by impregnating a web
of mat, generally of fiberglass material, with a bitumen, such as asphalt, and
applying
granules of desired color and/or contrast to that surface of the shingle that
would be the
upper surface of the shingle when the shingle is in an installed condition on
a roof.
Generally, the shingle is constructed to have multiple tabs separated by slots
cut inward
of the shingle from the lower edges of the tabs, to leave the tabs spaced-
apart relative to
each other. Sometimes the granules in the headlap or butt portion of the
shingle; i.e.,
above the tabs, are of a darker, less expensive nature, because generally the
headlap
portion of the shingle will be covered when shingles are laid up on a roof in
courses, with
shingles in a next-overlying course covering headlap portions of shingles in a
next
underlying course, and with each overlying course of shingles being staggered
longitudinally (leftward or rightward) relative to the next underlying course
of shingles.
It is also known in the shingle/roofing art that it is the tab portions of
shingles that
are weather-exposed in the installed condition, and thereby it is the tabs of
shingles that
can be lifted up by wind conditions, and that if such tabs are bent upwardly a
sufficient
amount, they can crack and, if the wind conditions are severe enough, can be
blown off
the roof
Accordingly, it is known to provide wind resistance for tabs of shingles that
are
installed on a roof. Such resistance is usually effected by application of
adhesive beneath
the tab portions of shingles, generally at the lower ends of the tabs, so that
the lower ends
of the tabs are adhesively secured to headlap portions of shingles in a next-
underlying
course of field shingles of a roof covering.
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Summary of the Invention
The present invention is directed to providing an asphalt shingle having a
base
mat impregnated with an asphalt material and having a headlap portion and a
tab portion,
with the tab portion comprising a plurality of tabs separated by slots, and
with adhesive
applied on the top surface of the shingle in the headlap portion above the
upper ends of
the slots, but wherein the headlap portion of the shingle has adhesive-free
zones above
the centers of the tabs.
The invention also includes a roof covering of shingles as described
immediately
above, wherein the shingles of overlying courses are offset longitudinally
(lefiwardly or
righwardly) relative to shingles in a next-underlying course, and wherein the
adhesive-
free zones in headlap portions of shingles are uncovered by shingles in a next-
overlying
course, such that no adhesive of a shingle of an underlying course is visible
through slots
of shingles in a next-overlying course.
This invention is also directed to a method of making an asphalt shingle that
includes applying a substrate layer to a layer of shingle-forming material,
wherein the
substrate layer has indicators at predetermined spaced-apart distances,
wherein those
indicators are sensed as the shingle-forming layer is moved along a
predetermined path
and then the placement of adhesive zones onto the headlap portion of the upper
surface of
the shingle forming layer is synchronized in response to the sensing of the
locations of
the indicators, and wherein the shingle-forming layer is cut into individual
shingles.
Accordingly it is an object of this invention to provide a single layer
asphalt
shingle as described above, or a multi-layer shingle with slots that go all
the way through
the multiple layers.
It is another object of this invention to provide a roof covering as described
above.
It is a further object of this invention to provide a method of making an
asphalt
shingle as described above.
It is a further object of this invention to synchronize the slot cutting step
of
making the shingle in response to the sensing of the indicators on the
substrate layer.
It is another object of this invention that the synchronizing step includes
changing
the relative placement of the adhesive zones in response to the sensing step.
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Brief Descriptions of the Drawing Figures
Fig. 1 is plan view of a shingle in accordance with this invention, showing
zones
of adhesive present in the headlap portion of the shingle, generally above the
slots that
separate tabs, and wherein adhesive-free zones are shown in phantom in the
headlap
portion of the shingle, above the centers of the tabs.
Fig. 2 illustrates an array of two shingles as they would appear if laid up on
a roof
in courses, with each shingle in a next-overlying course of shingles being
longitudinally
(leftwardly or rightwardly) offset relative to a shingle in a next-underlying
course, such
that the adhesive-free zones of shingles in a next-underlying course appear
through the
slots of shingles in a next-overlying course, such that the adhesive zones of
shingles in an
underlying course are covered by tabs of shingles in a next-overlying course,
and wherein
no adhesive in headlap portions of shingles in an underlying course is visible
through the
slots between tabs of shingles in a next-overlying course.
Fig. 3 is an illustration of a partial roof covering of shingles of the type
of Figs. 1
and 2.
Fig. 4 is a schematic illustration of various steps in the method of making a
shingle in accordance with this invention, wherein the relative placement of
the adhesive
zones and the slots is effected by changing the delivery of the shingle-
forming layer to
the adhesive applicator and the slot cutter.
Fig. 5 is an illustration like that of Fig. 4, but wherein the relative
placement of
the adhesive zones and the slots is effected by changing the position of the
adhesive
applicator and slot cutter.
Detailed Descriptions of the Preferred Embodiments
Referring now to the drawings in detail, reference is first made to Fig. 1,
wherein
the shingle 10 of this invention is illustrated in plan view as being
comprised of a single
layer of shingle material made of an asphalt impregnated mat with granules
applied to its
top surface 11. It will be understood that the shingle could alternatively be
one of multi-
layer construction with slots that go through the multiple layers. The shingle
10 has a
headlap portion 12 and a tab portion 13.
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In the embodiment shown, the tab portion 13 is a four-tab shingle having tabs
14,
15, 16 and 17 separated by slots 18 that extend from the lower edge 20 of the
shingle, at
the lower ends of the tabs, up to the headlap portion 12 of the shingle. It
will be
understood that the shingle could alternatively be a two tab, a three-tab or a
shingle with
five or more tabs.
It will be understood that the tabs 14-17 may contain decorative granules of
different colors and/or contrasts, as may be desired, and that the headlap
portion 12 may
have dark granules thereon, as shown, or any other type of granules.
It will also be understood that particulate material, such as sand, mica, or
other
material may be applied to the underside (not shown) of the shingle 10, as
desired.
Adhesive stripes 21,22 and 23 are shown in the headlap portion 12 of the
shingle
10, above the upper ends of the slots 18. In the embodiment shown, the stripes
21-23 are
shown in two vertically spaced-apart bands, with a pair of stripes 21,22
placed at the
lower end of the headlap portion 12 of the shingle 10, above the slots 18, but
just to the
left and right of the slots 18, and that the band of stripes 23 is placed
somewhat above the
lower band of stripes 21, 22, above the upper ends of the slots 18, with the
left and right
ends of the stripes 23, leaving adhesive-free zones 24 of a width "D" at the
lower end of
the headlap portion 12 of the shingle 10, between the stripes 21, 22 and
between adjacent
stripes 23, just above the center lines 25 (shown in phantom), midway between
left and
right edges 26, 27 of each of the tabs 14-17. These adhesive-free zones 24 are
shown in
the form of imaginary lines, as are the center lines 25, in order to depict
the portions of
the headlap portion 12 of the shingle 10 that will not have adhesive applied
thereto during
the manufacturing process. It will thus be understood that the adhesive-free
zones 24 as
well as the center lines 25 would not appear to be visible as phantom lines as
shown in
Fig. 1, but that the same are shown in phantom in Fig. 1, for illustrative
purposes only.
Between the adhesive stripes 21 and 22, there is a space that is free of
adhesive,
directly above each slot 18. This space is particularly adapted to be a
fastening zone, for
placement of a fastener, such as a nail, for fastening the shingle 10 to a
roof, either
manually, or by use of a nailing gun, stapling gun or the like.
With reference now to Fig. 2, it will be seen that a shingle 10, in accordance
with
this invention is presented as a shingle in an underlying course of shingles,
and that other
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shingles in that same course would be arranged end-to-end. A shingle 10' is
shown as
representing a shingle in a next-overlying course of shingles, and it will
likewise be
understood that a plurality of shingles 10' would be laid up in the next-
overlying course,
end-to-end.
Also, in Fig. 2, it will be seen that the tabs 14'-17' of the shingle 10' are
disposed
laterally (longitudinally) offset leftward and/or rightward, such that the
imaginary center
lines 25' are aligned above the slots 18 that separate tabs 14-17 of shingle
10.
In this manner, the tabs 14'-17' of shingles 10' in an overlying course of
shingles
will cover the adhesive zones 21-23 of shingles in the next-underlying course,
leaving no
adhesive zones visible through the slots 18' between adjacent tabs 14'-17' of
shingles 10'.
Also, with reference to Figs. 1 and 2, it will be seen that the adhesive-free
zones
24 on the top surface of the headlap portions of the shingles are of at least
a length L
corresponding to the length of the slots between tabs, and are at least of a
width W
corresponding to the width of the slots between the tabs, to slightly into the
headlap
region.
In Fig. 3, a building 30 is illustrated, having a roof 31 having a roof
covering 32
of shingles in accordance with this invention. In Fig. 3, a plurality of
courses 33-39 is
illustrated, with alternate courses having their shingles 10 staggered
longitudinally
(leftwardly or rightwardly) relative to shingles in a next-underlying course,
such that slots
18 of shingles 10 in a next-overlying course are centered above tabs of
shingles in a next-
underlying course and such that adhesive zones 21-23 in headlap portions of
shingles in
underlying courses are covered by tabs of shingles in next-overlying courses,
leaving no
adhesive visible through slots that separate tabs of overlying courses.
With reference now to Fig. 4, it will be seen that a web 45 of base mat is
provided, moving along a predetermined path in the direction of the arrow 46,
with the
web 45 being delivered to a bath 47 of bitumen material, preferably asphalt,
in a vessel
48, whereby a roller 50 picks up asphalt and applies it to the mat 45, to be
absorbed
throughout the mat 45 by being engaged between the lower roller 50 and an
upper roller
51, such that asphalt is applied throughout the mat 45, and to its upper
surface 52, as well
as its lower surface 53.
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The thus impregnated mat 45 is then delivered past a granule applicator 54,
having a plurality of granule applicator bins 55, 56, 57, 58 and 60 for
applying granules
to an upper surface 52 of the impregnated mat 45 by dropping them onto the
upper
surface 52, in the direction of the arrows 61, such that the granules thus
applied will
adhere to the upper surface 52 of the impregnated mat 45.
Granules of preferably smaller particulate material in the form of sand, mica
or
the like may be applied to the undersurface 53, if desired, by any of several
conventional
means known in the art.
It will be understood that, in the manufacture of a shingle-forming layer 45
in
accordance with this invention, the layer may be manufactured in the form of a
pair of
side-by-side shingle-forming layer portions simultaneously, in accordance with
that
portion of the disclosure of parallel shingle-forming layers as manufactured.
As the shingle-forming layer moves along its predetermined path as shown in
Fig.
4, a roll of substrate 59 is unrolled, as shown, and applied in the direction
of the arrow 62
shown in Fig. 4, to meet with the undersurface 53 of the shingle-forming layer
45, prior
to the passage of the substrate layer 59 and shingle-forming layer 45 around
the roller 63,
and then around the roller 65 as shown. The substrate 59 has adhesive on its
surface 64,
and is applied to the undersurface 53 of the shingle-forming layer 45, such
that it will
adhere thereto, and that, after the substrate 59 and shingle-forming layer 45
come
together around roller 63, they continue as a unit as shown around the roller
65.
A sensor 66, aimed at the undersurface 53 of the shingle-forming layer 45,
senses
predetermined, spaced-apart indicators (not shown) on the undersurface of the
shingle-
forming layer 45 as the shingle-forming layer 45 passes thereover, as shown at
67, and
transmits that information via transmission line 68, to a controller 70. The
controller 70
may be a programmable logic computer (PLC).
The substrate layer that is provided from roll 59 may be in the form of a tape
that
provides an indication in the form of a physical mark, a magnetic device, an
infrared
device, a hole, a photocell, that may be read by the sensor 66. The sensor 66
may take on
various forms, such as a lightness or darkness detector, a metal or magnetic
detection
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device, a barcode reader, an infrared detection device, a hole detection
device, a
photocell, a CCD array image reader or any other form of detection device,
many of
which are well known in the art and which can detect some difference caused by
a mark
or indicator of various types passing thereby.
The connection 68 between the sensor 66 and the controller 70 can be in the
form
of a wired connection, a signal line, or a wireless transmission line
providing a signal
from the sensor 66 to the controller 70, microprocessor, or computer of any
type.
The controller 70, in response to detection information received from the
sensor
66 sensing information from an indicator, delivers that information via
control line 71 to
a drive mechanism 72 for a take-up mechanism 73. The drive mechanism 72 can
adjust
the take-up roller mechanism 73 upwardly or downwardly as shown by the double
headed arrow 74 to adjust the delivery of shingle-forming layer 45, to
increase or
,
decrease the delivery of the shingle-forming layer after it passes around
roller 75, and
prior to its passing around roller 76, in order to synchronize the delivery of
shingle-
forming layer 45 to adhesive applicators 77 of adhesive applicator roller 78
as it rotates in
the direction shown by the arrow 79, to pick up adhesive 80 from adhesive
vessel 81 and
apply it to the surface 52 of the shingle-forming layer 45, as that surface
comes into
contact with the adhesive applicators 77.
Adhesive is thus applied in the form of stripes 82 prior to the shingle-
forming
layer passing around the roller 83.
It will be understood that the adhesive that is applied via the applicators
77, while
being described as being in the form of stripes, could be in the form of
squares, circles, or
any other geometric shape as may be desired, and as will function in
accordance with this
invention, all of which are embraced within the term "adhesive zones" or
"adhesive".
After application of the adhesive 82, and as the shingle-forming layer 45 then
passes around the roller 83, a doctor blade 84 may contact the adhesive 82, to
even out
the thickness of adhesive zones.
After passing around the roller 83, the shingle-forming layer continues in its
movement along a predetermined path, to pass around roller 85. The controller
70, via
control line 86 may control a drive mechanism 87, to move the same upwardly or
downwardly as shown by the double headed arrow 88, so that the drive mechanism
may
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adjust the position of a take-up roller mechanism 90, in response to a signal
received via
the transmission line 68 from the sensor 66, in order to adjust the placement
of the
shingle-forming layer 45 relative to a slot-cutting roller 91, after delivery
of the shingle-
forming layer 45 around roller 92.
The slot-cutting roller 91, rotating in the direction of the arrow 93, as
shown, may
be provided with one or more cutting blades 94, for cutting the slots between
adjacent
tabs in the shingle-forming layer.
Thus, the take-up mechanisms 72, 73; 87, 90 may be used to synchronize the
placement of adhesive zones on a surface of the shingle-forming layer in
response to the
sensing of the locations of the indicators, and may additionally adjust the
placement of
the slots such that they are synchronized in response to the sensor 66 sensing
the
locations of the indicators. In this regard, the synchronizing step includes
changing the
relative placement of any of the adhesive zones and the slots in response to
sensing the
locations of the indicators. This changing of the relative placement of the
adhesive zones
with or without the sensing of the relative placement of the slots can be
effected by
changing the delivery of the shingle-forming layer to the adhesive applicator,
and, if
desired, to the slot cutter as shown in Fig. 4.
Thereafter, the shingle-forming layer 45 may be delivered to any of various
mechanisms known in the art, such as a looper, a cooler (not shown), and
eventually to a
cutting roller 95 rotating in the direction of the arrow 96, as shown, with
the cutting roller
95 having at least one cutting blade 97 thereon, for cutting individual
shingles to desired
lengths.
With reference now to Fig. 5, an alternative arrangement is schematically
illustrated for changing the relative placement of the adhesive zones, and, if
desired, also
changing the relative placement of the slots in response to the sensing of
indicators. In
.. the arrangement illustrated in Fig. 5, to the extent that components are in
common with
the arrangement of Fig. 4, the same numerals will be used, and, to the extent
that there
are differences between the embodiments of Figs. 4 and 5 different numerals
will be
used, as shown and described.
In the embodiment illustrated in the schematic of Fig. 5, the controller 70,
via
control line 100 can control the movement of the drive mechanism 101, back or
forth as
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shown by the double headed arrow 102, to effect a change in position of the
adhesive
applicator 81 relative to the shingle-forming layer 45, as an alternative way
of
synchronizing the placement of adhesive zones 82 on the shingle-forming layer,
by
driving the adhesive applicator 81 via drive line 103, as shown. Similarly,
the controller
70, via control line 105, can control the movement of the slot cutter 94
through the drive
.. mechanism 106, via drive line 107, for movement of the slot cutter 94
backward or
forward as shown by the double-headed arrow 107, for synchronizing the cutting
of slots
in the shingle-forming layer 45, as an alternative way of changing the
relative placement
of the slots in response to the sensing of indicators on the shingle-forming
layer via the
sensor 66.
It will be apparent from the foregoing that various modifications may be made
in
the details of construction of the shingles, as well as in the methods of
manufacture of the
shingles of this invention, all within the spirit and scope of the invention
as defined in the
appended claims.
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