Process for in-line extrusion coatings onto roofing shingles during manufacturing and roofing shingles made by the process

Patent metadata

Field	Value
Publication number	US-11426756-B2
Application number	US-202016934185-A
Country	US
Kind code	B2
Filing date	Jul 21, 2020
Priority date	Jun 16, 2015
Publication date	Aug 30, 2022
Grant date	Aug 30, 2022

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.

First claim

What is claimed is:

1. An apparatus comprising:
a processing line configured to allow a mat of substrate material having a first surface and a second surface to be conveyed in a downstream direction;
a die positioned along the processing line and configured to eject a stream of molten polymeric material onto the first surface of the mat of substrate material as the mat is conveyed in the downstream direction to deposit a film of polymeric material on the first surface of the mat of substrate material;
a supply apparatus for supplying the molten polymeric material to the die;
a cooling apparatus configured to cool the film of polymeric material;
a coater positioned downstream from the cooling apparatus and configured to apply a coating of bituminous material in molten form to the second surface of the mat of substrate material;
wherein the coating of bituminous material is applied after cooling the film of polymeric material;
a granule applicator configured to apply granules to the coating of bituminous material;
a cutting station configured to cut the finished mat into individual shingles; and
a packaging station configured to bundle the individual shingles and package the bundles.

2. The apparatus of claim 1 wherein the die comprises a slot die.

3. The apparatus of claim 1 wherein the supply apparatus comprises a source of molten polymeric material and a pump configured to deliver the polymeric material from the source to the die.

4. The apparatus of claim 1 wherein the supply apparatus comprises an extruder.

5. The apparatus of claim 1 wherein the cooling apparatus comprises a chilled air blower.

6. The apparatus of claim 1 wherein the cooling apparatus comprises chilled rollers.

7. An apparatus comprising:
a processing line configured to convey a mat of substrate material having a first surface and a second surface along a processing path;
a die positioned along the processing line and configured to eject a stream of molten polymeric material onto the first surface of the mat of substrate material as the mat is conveyed in the downstream direction to deposit a film of polymeric material on the first surface of the mat of substrate material;
a supply apparatus for supplying molten polymeric material to the die;
a cooling apparatus configured to cool the film of polymeric material;
a coater positioned downstream from the cooling apparatus and configured to apply a coating of bituminous material in molten form to the second surface of the mat of substrate material; and
wherein the coating of bituminous material is applied after cooling the film of polymeric material:
a granule applicator configured to apply granules to the coating of bituminous material.

8. The apparatus of claim 7 wherein the cooling apparatus comprises chilled rollers.

9. The apparatus of claim 7 wherein the cooling apparatus comprises a chilled air blower.

10. The apparatus of claim 7 wherein the supply apparatus comprises a source of molten polymeric material and a pump configured to deliver the polymeric material from the source of molten polymeric material to the die.

11. The apparatus of claim 7 wherein the supply apparatus comprises an extruder.

12. The apparatus of claim 7 wherein the die comprises a slot die.

Assignees

• Building Mat Investment Corp
• Bmic Llc

Inventors

• Leitch Olan Thomas
• Keaten Mark Logan
• Kiik Matti

Classifications

• B26D3/10 Primary

  Making cuts of other than simple rectilinear form (cutting-out B26F) · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title

• D06N2211/06

  Building materials · CPC title

• D06N5/003

  coated with bitumen · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title